DJF5053-Jigs & Fixtures And Tooling Design

Title:Introduction Of Blow Moulding

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INTRODUCTION OF BLOW MOULDING

Word plastic is derived from the greek word meaning plastikos, mid 17th century (in the
sense ‘characteristic of molding’): from French plastique or Latin plasticus, from Greek plastikos,
from plassein ‘to mold.’ in reference and can be formed. The plastic can be cast, molded,
dimensions and connected to a variety of shapes very easily. surface finishing operations is
minimal even sometimes unnecessary. for komesial, plastic can be found in the form of sheets,
plates, films, rods and tubing. an increase in the use of plastic materials is due to several
factors, among many uses and production processes with a lower cost.

Plastic is a material consisting of any of a wide range of synthetic or semi-synthetic organic

compounds that are malleable and can be molded into solid objects. Plastics are typically
organic polymers of high molecular mass, but they often contain other substances. They are
usually synthetic, most commonly derived from petrochemicals, but many are partially
natural.[2] Plasticity is the general property of all materials that are able to irreversibly deform
without breaking, but this occurs to such a degree with this class of moldable polymers that their
name is an emphasis on this ability.

Due to their relatively low cost, ease of manufacture, versatility, and imperviousness to
water, plastics are used in an enormous and expanding range of products, from paper clips to
spaceships. They have already displaced many traditional materials, such as wood, stone, horn
and bone, leather, paper, metal, glass, and ceramic, in most of their former uses. In developed
countries, about a third of plastic is used in packaging and another third in buildings such as
piping used in plumbing or vinyl siding.[3] Other uses include automobiles (up to 20% plastic[3]),
furniture, and toys.[3] In the developing world, the ratios may be different - for example,
reportedly 42% of India's consumption is used in packaging.[3] Plastics have many uses in the
medical field as well, to include polymer implants, however the field of plastic surgery is not
named for use of plastic material, but rather the more generic meaning of the word plasticity in
regards to the reshaping of flesh.
 There are two types of plastics: thermoplastics and thermosetting polymers. Thermoplastics
are the plastics that do not undergo chemical change in their composition when heated and can
be molded again and again. Examples include polyethylene, polypropylene, polystyrene and
polyvinyl chloride.[20] Common thermoplastics range from 20,000 to 500,000 amu, while
thermosets are assumed to have infinite molecular weight. These chains are made up of many
repeating molecular units, known as repeat units, derived from monomers; each polymer chain
will have several thousand repeating units.

Thermosets can melt and take shape once; after they have solidified, they stay solid. In the
thermosetting process, a chemical reaction occurs that is irreversible. The vulcanization of rubber
is a thermosetting process. Before heating with sulfur, the polyisoprene is a tacky, slightly runny
material, but after vulcanization the product is rigid and non-tacky.
 Information About Plastic
materials used

Polyethylene terephthalate is not made is not made in a single process. It is made by

the reaction of two chemicals known as Purified terephthalic acid (PAT) and ethylene
glycol (EG).These two chemicals form Polyethylene terephthalate along with other types
of plastic, used in variety of applications such as engineering, nylon production, etc.

Below are some Properties of Polyethylene terephthalate

•Density: 1.38~1.40g/mm3

•Melting Temperature: 254-256°C

•Crystallinity: >=45%

•Glass Tempurature

Fig02: Repeating unit of Polyethylene terephthalate.

PET is a long chained molecule with the repeating unit displayed above, resin, a bluish
white substance, is made from poly condensation of terephthalic acid and ethylene
glycol. Resin manufacturers supply PET in the form of small pellets, each weigh about
0.05 grams.Being transparent, PET can reach a tensile strength of about 1/3~1/2 of
steel's.The number of PET repeating units per chain, used in the bottle industry to make
plastic bottles is about 100 to 155, usually labeled in terms of resin IV.
Uses of Polyethylene terephthalate
Also known as PET, is a thermoplastic is which is one of the types of plastic amongst million others. By
far the most useful type of plastic, PET bottles are used mostly in the beverage industry, where the
bottles are filled with the particular beverage and supplied around the globe. It can be water, fresh juice,
or any other beverage. Some of the most common uses would be bottling of mineral water, edible oil,
juice, cosmetics, pharmaceutical, etc.

Main Advantages of PET

 Pure – PET does not involve, by reacting with the food or beverage which is kept within the
container. Therefore, PET complies with international food contact regulations.

 Lightweight – 10 times, lighter than a glass pack, PET bottles, hence, reduces shipping costs by
30%. If a glass and PET bottle having the same size is compared in volume it can store, PET will
come in first, as its wall is thinner.
 Crystal Clear – The product looks clean and healthy and in physical good shape. These attract
attention and increases the sales of the products contained within it.
 No Leakage – Due to the absence of a weld line in the bottom the PET bottles leakage does not
occur.
 Design Flexibility – Can be designed in all shapes and sizes, designs and colors.
 Recyclable – As it is one single material, PET bottles can be washed and crushed into flakes and
remolded into shape. It has other uses after it is recycled such as for strapping, making carpets,
etc.

Production of PET bottles

Usually PET bottles are manufactured using 2 different methods.

These are :-

1. One-Step "hot perform" method.

2. Two-Step "cold perform" method.

Step-one "hot perform" method

This method is just one step, from PET granule to finished bottles, all the processors are done in one
integrated machine. That is from the injection mold of the preform to the removal of the preform from the
injection cavity, and to stretch blow the preform to a bottle all in one machine, while the temperature
remain constantly high for the whole process as injection molding and blow molding, the material should
in an elastic form. This method saves a lot of energy as the material only has to be heated only once, that
is when it is injected to the cavity to produce the preform. The One-Step method is commonly used in
small or medium PET production companies.
Step-two"cold perform" method
This method has 2 distinct machines to perform the injecting and blow moldings. The preform is injected
into shape on the first machine, and then the preform is reheated as the it isn't brought directly to the blow
molding machine and blown on the second machine. This method is not very efficient as the heat lost is
considered as a loss of energy. But this machines are fully automated.This method is used in most
medium to large scale PET production companies.This machine is 200% more efficient than the one-step
machine.

Fig04: Two-Step “cold perform” method, Fully automated machine.

Usually the Two-Step Method is used in production of PET bottles.

Driying and Dehumidifying of PET

PET is a type of plastic that absorbs moisture with an average water content of 0.05%. To increase the
quality of the preform in transparency and physical performance the PET is dried to reduce the water
content of the PET resin to less than or equal to 0.005%. The following drying methods are used.

 Oven Dry – The drying is done at a temperature of 110°C for a maximum of 8 hours after which
PET will start to fail. The trays with PET inserted into the oven are about 50mm thick. The oven
isn't connected to the injection machine ant the dried PET is moved manually.

 Hopper dryer– The widely used method of drying PET as it very economicaland works along with
an autoloader, therefore the process is continuous and automatic.
 Fig5: A hopper dryer used to dry PET granules.

 A Dehumidifier – Similar to the hopper dryer this also words together with an autoloader, but it is
the most efficient method in drying. The PET dries in at a temperature of about -32°C, thereby
increasing the durability and the final finish of the PET bottle.

Fig06:A Dehumidfier used to dry PET granules.

The Optimum drying temperature would be about 150~170°C. The best duration for drying the PET would
be about 4 hours. The drying time should not surpass 7~8 as will deteriorate the PET.
Injection Molding of the PET Preform

Fig7: An Injection molding machine with essential equipment attached.

The above picture shows an injection molding machine with the autoloader and dryer other essential
equipment needed in the process.

Fig8: Schematic illustration of the injection molding process.

The process is simple, the heated PET which is in the molten form is injected into the injection chamber
(2),by the rotation of screw barrel (1) within the machine, until the chamber is full.

Once the chamber is full, the screw pushed forward (3) to fill the injection cavity with molten plastic
through the nozzle into the mold.

The temperature within the injection molding machine are different, at the rear end of the machine the
temperature should be around 275°C, at the middle of the machine about 282°C, at the nozzle about
280°C. And at the runner the temperature should be around 270°C for the bottle formed to have optimum
specifications. (These temperature may vary a little depending on the design of the mold)

Fig9: PET Preform Mold

 Fig10: Preform being Heated

Subsequently the molten plastic within the mold,called the preform, should be cooled. The cooling water
used to cool the perform should be in the temperature range between 15~20°C, the pressure also has to
be controlled, therefore a water chiller is used. The pressure should be kept around 500,000 Pa or 5Bar.

The PET preform is ejected (4) from the mold. Now the preformis reheated to the temperature until it is
suitable for the blowing process.

Fig11: A Typical Water Chiller.PET Preforms

 Fig12:PET Preforms

Stretch Blow Molding of the PET Preform to Container

The Following process in production of PET is a type of Blow molding called Stretch Blow molding, as air
is blown into the preheated PET Preform.
The other types of Blow molding are:-

1. Extrusion Blow molding

Fig13: Extrusion Blow molding Process.

2. Injection Blow molding

Fig14:Injection Blow molding Process.

 Blow molding is a process of forming hollow object by blowing a blowing into thermoplastic, in this
case PET Preform, which is heated and in its maximum elastic condition. The blow molding process used
in production of PET Bottles is Stretch Blow Molding.

This process is also called Biaxial orientation blow molding as the preform is first stretched by the blowing
device, for the reason that the molecules of the preheated preform is aligned in one direction and all
parallel to each other, then blown in right-angles to the direction of the molecules being aligned.

The theory behind the how this works is, when the PET is heated the long-chained molecules can loosen
then as an alternative to breaking, they orient when stretching. Therefore,this (stretch blowing)is also
called biaxial orientation as it deals with two axes stretching.

This stretching increases the strength of the material because instead of the molecules in the material act
separately, they act as one whole unit.

The following characteristics are improved or increased as a result of this stretching the PET Preform
before blowing into it.
  Impact Strength
 Barrier
 Chemical Resistance
 Tensile Strength

The ideal temperature for orientation for PET is 105°C.

The compressed air () blown into the PET Preform is first cleanedthrough an air purifier (). The air must
be cleaned since air contaings moisture and oil, which will directly affect the quality of the bottle. The PET
preform is mounted on to the blowing machine (). After purifying, the air is blown into the preheated PET
preform using a blower on to the mold ().

The thickness of the Stetched blown bottels are 0.25~0.38mm. This thickness is suffiecient as the
orientation will increase the products' quality.

Possible Defects while production of PET Bottles

One of the Major defects in the production of PET Bottles is the production of Acetaldehyde.

This compound also called as AA, is the taste of an acidic taste in most citrus fruits. This taste in the
bottle can ruin the taste of the drinks, especially if its water as the taste of pure water isn't strong enough
to disguise the taste of AA, unlike the sweet flavors. If the presence of the AA is noticed the quality of the
product literally, goes down the drain.

AA is produced along with the PET when the temperature of the material is higher than 260°C, this
temperature is reached inside the injection molding of the preforms, therefore is the process is not
maintained correctly, AA is produced along with the PET preform.

Decreasing the melt temperature and the residence time and help reduce the production of AA.

Other forms of defects are briefly mentioned below.

 OH- or COOH- end groups doesn't becomes non-reactive.

 Amount of poly-functional macromolecules increases.

 Hydroxide and peroxide groups build up at the surface of the PET and etc.
Fig16:The Total PET Bottle Production Process
Manufacturing Costs
Process: PET bottles manufacturing process involves two basic stages of pre-form manufacturing and
Bottle Stretch Blow Moulding. In a one-step process, the PET bottles are made directly from the resin.
Both the pre-form manufacturing and stretch blow moulding is performed on a single line. (see Table-I)

Machinery Number Indian Rupee

Injection Molding Machine 1 750000

Blow Molding Machine 2 800000

Compressor 1 150000

Cooling Tower 1 150000

Chiller Unit 1 80000

Lather 8ft, refurnished 1 110000

Lathe 5.5ft 1 72000

Pillar Drill 26 inches with pump 1 50000

Facer 1 150000

Shaper 1 125000

(These are indicative estimates, therefore, the intended investor must make his own calculations by
market survey). Injection moulding machines of two different sizes are required as the proposed
production mix depends upon different sizes. The usual machinery delivery time is 15-20 days, while
import can take up to 4 months' time, depending upon the availability. The stretch blow moulding
machines are being manufactured locally. Lathe machines, pillar drill, facer and shaper, required for the
workshop, are also manufactured locally. (see Table-II)

Human Resource Number Annual Salary

CEO 1 360000

Production Manager 1 192000

Accountant 1 96000

Injection Machine Operators 2 168000

 Blow Machine Operators 2 168,000

Pre-form Handler 1 30,000

Helpers 4 120,000

Guards 3 108,000

Land and building: An area of about 5,000 sq. ft would be required for the project. Management building
100, production Area 1,800, raw material store 300, finished goods store 500, loading area 700,
workshop area 850, cooling tower/chiller 700 sq. ft.

Key assumptions: 288 days p.a. Annual production capacity 5,840,640 bottles, capacity utilisation (1st
Year) 40 per cent, capacity growth rate (yearly) 2 per cent, maximum capacity utilisation 95 per cent, first
year production utilisation 2,304,288 bottles. (see Table-III)

Others Growth Rate

Electricity 10%

Wages 10%

Office equipment 10%

Machine maintenance 5%

Initial approximate cost/Kg (Rs) 81, Sales Tax 15 per cent, freight cost per kg 1.22. Weighted average
cost of raw material per bottle may come to Rs2.81. Other heads include administrative costs,
promotional expenses, insurance, electricity and taxes. (see Table-IV)

Other Depletion Rate

Building & infrastructure 5%

Machinery & Equipment 10%

Furniture & Fixtures 10%

Project life 10 years

Debt: Equity Ratio 50:50

Interest rate on long term debt 16%

 Discount rate for calculation of NPV 20%

Raw Material Consumption per Bottle And the final costs. (see Table-V)

Size Weight Cost (Indian Rupees) per 100 Bottles Cost (Sterling Pounds) per 100 Botttles

0.5 Liter 15.5 146 1.98

15 Liter 33.3 313 4.25

5 Liter 74.7 702 9.53

Weighted average cost of raw material per 100 bottles comes to about £3.82. While average sale price
per 100 bottles may be £9.21.