HyPET Preform Systems

Features & Options Booklet

Version 9.11 — May 2011

 HyPET Preform Systems

HyPET Preform systems deliver...

• Turnkey solutions for every application and volume

• Complete, integrated work cells
• Industry leading productivity
• Highly repeatable and reliable performance
• Broadest product line available
• Optional High Performance Package (HPP)
• Optional Recycled Flake Package (RF)
• Optional Flex Mold for flexible products and quick mold changes
• Combining HyPET with Husky Services ensures customers achieve the lowest total cost of ownership
over the product lifecycle

Version 9.11 — May 2011

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HyPET Preform Systems — Mold Matrix

Maximum Part Dimension*

Cavity Pitch
HyPET

HPP
Body EOAT

Flex
Vertical x Horizontal
RF
Machine Cavities 'T' Diameter 'Z' Diameter
Diameter Position
(mm) (mm) (mm) (mm) (max)

• 2 220 110 110 108 2

• 4 95 x 190 90 90 88 2

• 6 95 x 190 70 70 68 2

• • 8 85 x 180 63 63 61 2
HyPET 120
• 12 75 x 170 48 53 43 3

• • 16 63.5 x 160 43 48 36 3

• • 24 60 x 140 38 43 38 3

• 32 50 x 130 30 34 30 3

• 6 140 x 240 110 110 108 2

• 8 120 x 210 90 90 88 2

• 12 95 x 190 70 70 68 2

HyPET 225 • 16 85 x 180 63 63 61 2

• 24 75 x 170 48 53 46 3

• 32 63.5 x 160 43 48 40 3

• 48 50 x 140 30 34 30 4**

• 8 140 x 240 110 110 108 2

• 12 120 x 210 90 90 88 2

• 16 95 x 190 70 70 68 2

• 24 85 x 180 63 63 61 2

HyPET 300 • 32 75 x 170 48 53 46 3

• 48 63.5 x 160 43 48 40 3

• • • 72 60 x 140 38 43 38 3

• • • 72 50 x 140 30 34 30 4**

• • 72 50 x 155 30 34 30 4

• 12 140 x 240 110 110 108 2

• 16 120 x 210 90 90 88 2

• 24 95 x 190 70 70 68 2

• 32 85 x 180 63 63 61 2

HyPET 400 • 48 75 x 170 48 53 43 3

• 72 63.5 x 160 43 48 40 3

• • • 96 60 x 140 38 43 38 3

• • • 96 50 x 140 30 34 30 4**

• • 96 50 x 155 30 34 30 4

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HyPET Preform Systems — Mold Matrix (continued)
Maximum Part Dimension*
Cavity Pitch
HyPET

HPP
Vertical x Horizontal

RF
Machine Cavities Body EOAT
'T' Diameter 'Z' Diameter
Diameter Position
(mm) (mm) (mm) (mm) (max)
• 96 60 x 140 38 43 38 3
• 96 50 x 140 30 34 30 4**
HyPET 400 S
• 96 50 x 155 30 34 30 4
• 112*** 50 x 140 30 34 30 4**

• 16 140 x 240 110 110 108 2

• 24 120 x 210 90 90 88 2
• 32 95 x 190 70 70 68 2
• 48 85 x 180 63 63 61 2
HyPET 500
• 72 75 x 170 48 53 43 3
• 96 63.5 x 160 43 48 40 3
• • 128 60 x 140 38 43 38 3
• • 144 50 x 140 30 34 30 4**

• • 144 67.5 x 160 43 48 40 3

HyPET 650 • 168 60 x 150 38 43 38 3
• 192 50 x 155 30 34 30 4

* Part dimensions are for reference only. Other preform specific geometry can affect suitability. Preform drawings required to confirm pitch.
** For 4 position cooling maximum body diameter cannot exceed 26.5 mm.
*** Preform length minimum 65 mm; Maximum 205 mm for HyPET 90 - 500, 155 mm for 112 cav HyPET400 S HPP and 180 mm for HyPET 650

Version 9.11 — May 2011

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Preform System Options
Reciprocating Screw (RS) Injection Unit

2-Stage Injection Unit

HyPET with HPP

The Husky High Performance Package (HPP) is the result of refinements to the entire HyPET preform system,
including mold, robot, injection unit, clamp and auxiliary equipment. Only through this coordinated effort has it been
possible to significantly improve molding cycle times, while still producing preforms with superior levels of quality.
This new technology typically reduces cycle times by approximately 15% compared to previous industry-best cycle
times.

The productivity improvements offered by HyPET with HPP further reduce the cost of PET packaging, making it even
more competitive with glass, metal and carton alternatives.

Flex Mold
Flex Mold is a flexible, low cavitation PET preform mold. Available in 8, 16 or 24 cavities, Flex Mold is ideal for lower
volume preform producers (producing between 5 and 30 million units each year) or those manufacturers who produce
a range of preform families.

Flex Mold:
• Reduces mold change times by one third compared to conventional
designs
• Eliminates the need to cool down and reheat the hot runner during a
preform change
• Minimizes the number of components that need to be replaced for a new
preform design
• Includes adjustable cams that can be used for a variety of preform
designs, thereby reducing conversion cost
• Uses post-mold cooling tubes mounted on lightweight “take-off bars”
• Includes a mold water purge system to improve mold change time and
reduce water spillage

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Clamp – Injection Unit Matrix
Shot Capacity RS Injection -
2-Stage Injection — Screw Diameter (mm)
Clamp Shooting Pot of PET Screw Diameter (mm)

(g) (lb) 45 65 80 E85 E100 E120 E140 E140L E155L

RS80 1450 3.2

HyPET 120
P85/95 2200 4.9

HyPET 225
P85/95 2200 4.9

P100/110 3344 7.4

P85/95 2200 4.9 Ф Ф
P100/110 3344 7.4
Ф
Ф
HyPET 300
P100/120 3980 8.8
Ф
Ф
P120/130 5770 12.7
Ф
HyPET 400
P100/110 3344 7.4 Ф
Ф
P100/120 3980 8.8
Ф
HyPET 400S*
P120/130 5770 12.7 Ф
Ф
Ф
HyPET 500
P120/130 5770 12.7 Ф
Ф
Ф
P155/150 8048 17.7
Ф
HyPET 650
P120/130 5770 12.7 Ф
P155/150 8047 17.7
Ф

HyPET | Ф HPP
* HyPET 400S is only available as HPP

Throughput (kg/hr)
RS Injection -
Screw Diameter 2-Stage Injection - Screw Diameter (mm)
Speed Resin IV Type (mm)
E155
RS80/80 E85 E100 E120 E140 E140L
L
HyPET 285 400 520 700 890
High IV
HPP na 440 620 840 1070
Co-polymer
Standard HyPET 285 400 530 710 900
Low IV na
Speed HPP na 440 620 840 1070
Homo-polymer HyPET 285 350 450 590 760
or Special High & Low IV
Co-polymer† HPP na 360 490 650 830

HyPET 480 600 800 1000 1150 1340

High IV
HPP 575 720 960 1200 1380 1610
Co-polymer
HyPET 500 630 830 1050 1200 1400
Increased Low IV na
Speed HPP 575 720 960 1200 1380 1610
Homo-polymer HyPET
or Special High & Low IV 380 490 650 830 960 1140
Co-polymer† HPP

* Throughput values for 2-Stage and RS Injection units use a HyFLO and standard RS screw, respectively. Throughputs may be reduced for colorants or additives.
†
Throughputs for homo-polymers and special co-polymers require nozzle re-mixers to achive stated values.
na — not applicable

Version 9.11 — May 2011

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METRIC SPECIFICATIONS

Clamps
HyPET HyPET 120 HyPET 225 HyPET 300 HyPET 400 HyPET 500 HyPET 650

Clamp Force kN 1200 2250 3000 4000 5000 6500

Tiebar Spacing (H x V) mm 500 x 500 660 x 660 780 x 780 920 x 920 1020 x 1120 1120 x 1470
Clamp Stroke* mm 670 / 835 755 / 920 1150 / 1325 1087 / 1252 1175 / 1350 1250 / 1515
Shut Height Range mm 485 / 650 585 / 750 575 / 750 585 / 750 585 / 750 585 / 850
Daylight mm 1320 1505 1900 1837 1925 2100
Ejector Stroke mm 200 200 200 200 200 200

Weight kg 4,504 7,802 11,984 18,098 22,500 32,800

HyPET 400
HyPET 300 HyPET 500 HyPET 650
HyPET HPP HyPET 400 S
HPP HPP HPP HPP
Clamp Force kN 3000 4000 5000 6500
Tiebar Spacing (H x V) mm 780 x 780 920 x 920 1020 x 1120 1120 x 1470
Clamp Stroke* mm 1105 / 1280 1100 / 1275 1175 / 1350 1300 / 1575
Shut Height Range mm 575 / 750 575 / 750 575 / 750 575 / 850
Daylight mm 1855 1850 1925 2150
Ejector Stroke mm 200 200 200 200
Weight kg 11,984 18,098 22,500 32,800

*Available stroke at maximum/minimum shut height.

2-Stage injection Units

Shooting Pot P85/95 P100/110 P100/120 P120/130 P155/150
Stroke mm 300 340 340 420 440
Maximum Shot Size g of PET 2200 3344 3980 5770 8047
Minimum Shot Size g of PET 245 372 442 641 984

Extruder E85 E100 E120 E140 E140L E155L

Transfer Capacity g of PET 2610 3613 5200 7966 7966 8680
Total Injection Unit Weight (no oil) kg 10726 13150 14508 17450 20360 27350

RS Injection Units
Injection Model RS80/80
Maximum Shot Size g of PET 1,450
Minimum Shot Size g of PET 240
Weight - HyPET 90* kg 14,700
- HyPET 120 kg 14,700

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IMPERIAL SPECIFICATIONS

Clamps
HyPET HyPET 120 HyPET 225 HyPET 300 HyPET 400 HyPET 500 HyPET 650
Clamp Force ton 135 253 337 450 562 730
Tiebar Spacing (H x V) in 19.7 x 19.7 26.0 x 26.0 30.7 x 30.7 36.2 x 36.2 40.2 x 44.1 44.1 x 57.8
Clamp Stroke* in 26.4 / 32.9 29.7 / 36.2 45.3 / 52.2 42.8 / 49.3 46.3 / 53.1 49.2 / 59.6
Shut Height Range in 19.1 / 25.6 23.0 / 29.5 22.6 / 29.5 23.0 / 29.5 23 / 29.5 23 / 33.4
Daylight in 52 59.3 74.8 72.3 75.8 82.7
Ejector Stroke in 7.9 7.9 7.9 7.9 7.9 7.9

Weight lb 9,930 17,200 26,420 39,900 49,604 72,311

HyPET 400
HyPET 300 HyPET 500 HyPET 650
HyPET HPP HyPET 400S
HPP HPP HPP HPP
Clamp Force ton 337 450 562 730
Tiebar Spacing (H x V) in 30.7 x 30.7 36.2 x 36.2 40.2 x 44.1 44.1 x 57.8
Clamp Stroke* in 43.5 / 50.4 43.3 / 50.2 46.3 / 53.1 51.2 / 62
Shut Height Range in 22.6 / 29.5 22.6 / 29.5 22.6 / 29.5 22.6 / 33.5
Daylight in 73 72.8 75.8 84.6
Ejector Stroke in 7.9 7.9 7.9 7.9
Weight lb 26,420 39,900 49,604 72,311

*Available stroke at maximum/minimum shut height.

2-Stage injection Units

Shooting Pot P85/95 P100/110 P100/120 P120/130 P155/150
Stroke in 11.8 13.4 13.4 16.5 17.3
Maximum Shot Size g of PET 2200 3344 3980 5770 8047
Minimum Shot Size g of PET 245 372 442 641 984

Extruder E85 E100 E120 E140 E140L E155L

Transfer Capacity g of PET 2610 3613 5200 7966 7966 8680
Total Injection Unit Weight (no oil) lb 23646 28990 31984 38470 44886 60296

RS Injection Units
Injection Model RS35/35
Maximum Shot Size g of PET 260
Minimum Shot Size g of PET 45
Weight - HyPET 90* lb 23,589
- HyPET 120 lb na

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Features and Options

HyPET HPP

Clamp
● ● Hydro-mechanical 3-platen design
● ● Reflex platens distribute clamping force evenly and reduce required tonnage
● ● Wide tie bar spacing permits higher cavitation molds
● ● Linear bearings support the moving platen directly on the machine base
● ● Automatic shut height calibration
● ● Closed loop tonnage control
● Closed loop mold stroke control
● ● High force hydraulic ejector system with in-platen boosters
● ● Proportional control of ejector speed and pressure for precise part transfer
● ● Core air function to assist part transfer
● ● Regenerative mold stroke hydraulics for energy efficiency
● ● High efficiency mold cooling water system
● ● Pneumatic hot runner valve gate control
C8505 – Crating for sea shipment
○ ○ Exposed steel surfaces are coated with rust inhibitor and each unit of the system is vacuum-
sealed in plastic with desiccant for corrosion protection.
C8515 – Dehumidification enclosure (picture on page 12)
Gates above the clamp & robot to retain dehumidified air in the molding area. The enclosure
○ ●
consists of two interlocking halves mounted on rollers allowing easy access for mold installation.
(Mold dehumidifier to be purchased separately.)
C4711 – CE Compliance
○ ○
The machine is built to current European Union injection molding machinery standards.
C7805 – Safety Drop Bar
○ ○
This device provides a physical obstruction to impede the closing motion of the moving platen.
C8518 & C8519 – CoolPik Air Filtration
○ Provides a filter box and filter assembly integrated into the CoolPik Blower to minimize dust
coming from the air cooling circuit of the CoolPik device.

Hydraulics
Independent servo valve control of clamp tonnage, mold stroke and injection for precise, reliable
● ●
control of key machine functions
● ● Variable displacement axial piston pumps for energy-efficient power delivery
● ● High-efficiency, water-cooled drive motor
● ● Easily accessible service areas including filter elements, pumps, motor and hydraulic valves
● ● Oil tank designed to prevent entry of environmental contaminants
● ● High-flow bypass oil filtration with pressure drop monitoring
● ● Noise reducing, fully enclosed power pack
● ● Quick connectors for hydraulic gauges (supplied) at key hydraulic test points
C9501 – Accumulator charging kit
○ ○ Includes hardware required for charging the accumulator system following machine shipment and
for subsequent maintenance. Does not include nitrogen.

● Standard feature
○ Optional feature
Version 9.11 — May 2011
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Features and Options

HyPET HPP

Injection Unit
● ● Husky HyFLO screw design
Separate extrusion and injection functions allow for continuous plasticizing, low acetaldehyde (AA)
● ●
generation and greater energy efficiency (2-stage injection units)
● ● Closed-loop fill velocity control and closed-loop pack pressure control for shot-to-shot precision
● ● Resin feed tube for direct connection to resin dryer
● ● Feed throat temperature monitoring
● ● Pneumatic hopper shut-off with dumping feature to control resin supply from the operator interface
● ● Ring check valve on RS injection units
C4153 – Feed throat magnet (picture on page 14)
○ ○ A magnet, mounted in a slide out drawer at the feed throat, removes any ferrous particles in the
resin.
C4160 – Walkway (picture on page 14)
○ ○
Platform, ladder and railing for access to the injection unit.
C8527 – Machine nozzle remixer (picture on page 15)
○ ● A set of mixing elements integrated into the machine nozzle for more uniform color and
acetaldehyde (AA) dispersion throughout the mold cavities.
C8526 – Increased Screw Speed
○ ○ Larger electric drive motor and hydraulic pumps resulting in approximately 10% higher
plastification rates than standard (for co-polymer PET).

C8525 – Mixcel Screw

A screw designed for additive mixing applications. The Mixcel screw is able to handle liquids from
○ ○ 0.05 to 0.2%, master batch from 1 to 4%, and micro-pellets from 0.1 to 1%. This screw design is
available for legacy and compatibly reasons only and has been replaced on all new PET
machines with the HyFLO screw.

Robot
● ● Side-entry robot with up to four positions of water-cooled take-out tubes
● ● CoolPik internal preform air-cooling
● ● Self-aligning take-out plate for quick installation
● ● Reversing flat belt conveyor

● Standard feature
○ Optional feature

Version 9.11 — May 2011

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Features and Options

HyPET HPP Flex

Preform Molds
● ● ● Fully optimized and tested at Husky, producing preforms within specification at target cycle.

● ● ● Detailed preform inspection report

● ● ● Detailed process set-up information
● ● ● Pneumatic valve gate hot runner
● ● ● Lifting bar, latches and mold feet
● ● ● Roller cam actuated neck ring slides
● ● ● Water cooled stacks, optimized based on application
● ● ● Fast mold-to-machine alignment for fast installation
● ● ● Built-in water manifold with quick-disconnect hose fittings
● ● ● Air assisted preform transfer
● ● ● Mold Manual
● ● ● Stainless steel mold shoes and inserts

● Integrated preform conditioning system

Optical part detection (picture on page 15)

○ ● ○ Allows the robot to retract from the molding area immediately after preforms have
completed transfer, which improves cycle time.
Mold maintenance tool kit
○ ○ ○ A complete set of mold tools designed specifically for maintenance of Husky preform
molds.
Two-piece cavities (picture on page 15)
○ ● ○
The cavity flange can be replaced separately from the cavity body.

○ ○ ○ Molds Spares Package (Standard or customized to your requirements)

○ ○ ○ EcoBase preform light weighting

○ ○ ○ Timing lugs, ratchets or other preform specific features

○ ● ○ Post mold water cooled product handling up to four position (when applicable)

● Standard feature
○ Optional feature

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Features and Options

HyPET HPP

Polaris Controls
● ● PC-based machine control for fast response time, reduced cycle times and shot-to-shot accuracy
Simple, intuitive control of the system including robot, mold and auxiliaries through a touch screen
● ●
color monitor
● ● Real time statistical process & quality control (SPC/SQC)
● ● Remote monitoring and diagnostics via a built in modem or network card
● ● Secure system with five levels of password-protected user access
● ● Storage of over 1000 machine setups
● ● Automatic heater power reduction during machine stoppages for a user-selectable duration
Precise position monitoring of clamp, injection unit and ejector via automatically calibrated ultrasonic
● ●
position transducers with 5 micron resolution
● ● Soft start of pump motors reducing peak current by 30%
● ● Graphical display of injection speed, injection pressure, clamp pressure, and platen speed
● ● On-screen switching between English and a second language
● ● SmartStart and SmartStop software provides automated startup and shutdown
● ● Auto purge provides an automated purging sequence upon startup
○ ○ Soft drop device interface
C6002 - Host computer interface
○ ○ Communication interface to exchange data between the machine and a host computer (not
supplied).
C4150 - Control outlet for mixer/blender (115V, 6A) (picture on page 14)
A 10-pin connector located on the right hand side of the control cabinet. Both male and female
connectors are supplied.
○ ●
C4152 – Control outlet for mixer/blender (230V, 6A) (picture on page 14)
A 10-pin connector located on the right hand side of the control cabinet. Both male and female
connectors are supplied.
C6200 – Convenience Outlet package (picture on page 14)
○ ○ One single-phase and one three-phase outlet mounted near the injection end of the machine on
the right hand side of the machine control cabinet.
C6610 – Set point change tracking
○ ○ Capability to track the reasons for set point changes. Each set point change requires the operator
to enter a reason from a pre-defined list of up to 100 customer configurable codes.
C6004 – Audible alarm (picture on page 14)
○ ○
Cycle interruption alarm on top of alarm light assembly.
C6501 – 4-Wire main breaker
○ ○ Provides a disconnect for all three phases and the neutral. Does not include neutral disconnect
breaker for separate drop to integrated mold heats.
C6510 – High temperature environment package
Includes independent water shut-off valves for stationary platen, moving platen and robot cooling
circuits. The pneumatic shut-off valves will be installed on the inlet side of each cooling circuit. In
○ ○
addition to the shut-off valves, Software will be added to reduce the mold sweating while the
machine is idle. Provides also desiccant breather for the tank to avoid air condensation in the oil
reservoir.

● Standard feature

○ Optional feature

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Features and Options

HyPET HPP

Polaris Controls (continued)

D6011 – Auxiliary device interface (Euromap)
○ ○ Interfaces for linking up to four pieces of auxiliary equipment to the machine control. Each device
type must be specified at the time of machine purchase.

D6018 – Auxiliary device interface (SPI)

○ ○ Interfaces for linking up to four pieces of auxiliary equipment to the machine control. Each device
type must be specified at the time of machine purchase.

D6601 – Third language support

○ ○
Ability to switch the operator interface to a third language.

C8549 – C8555 Hot Runner control package for preform molds

Ability to control the hot runner heat zones for all standard Husky HyPET molds. The package
● ●
includes individual percentage controlled nozzle tips, and thermocouple controlled sprue and
manifolds.

C8557 – Husky Auxiliary Equipment User Interface

To compliment the performance of the Husky Auxiliary Equipment Husky also offers a controls
○ ○
interface that provides the machine operator with direct access to the control set points of the
auxiliary equipment.

C8559 – Mold Cooling Water Monitoring Package

The Temperature and pressure of mold water and EOAT In and Out connections are displayed
○ ○
on the HMI for real time monitoring. The six chilled water temperatures and six chilled water
pressures are included in the datalogging/SPC function.

General Options
C1003 – Preform system test
○ ○ Includes the integration of the customer’s mold and machine and a 4-hour run. Resin is not
included.

D1001 – Special color

The machine and robot will be painted in customer specified colors. This option covers only direct
○ ○
substitution of standard Husky beige, yellow and orange colors. The use of two component paints
is not included.

C6504 – Voltage surge suppression

○ ○ Provides increased resilience to voltage surges up to 2500V, protecting sensitive electronic
equipment.

C8500 - C8502 - Machine spares package

○ ○
Basic, standard, or comprehensive.
C6603 & C6604 - Additional manuals
○ ○
CD only or CD and paper.

● Standard feature

○ Optional feature

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Features and Options

HyPET HPP

Preform Handling and Auxiliary Equipment

Softdrop system
Deposits preforms into containers more gently to avoid cosmetic defects. The system diverts
○ ○
preforms to an empty container after part count has been reached, allowing the full container to
be taken away and replaced.

Mold dehumidifier
○ ○
Provides dry air to the machine enclosure to prevent condensation on the mold.

Resin dryer
○ ○
Reduces moisture content of the resin to a level suitable for molding.

Chiller
○ ○
Cools mold process water to the temperature required for preform molding.

Additive doser
○ ○
Adds liquid or Masterbatch additives.

High Performance Package (HPP)

C8503 – Machine High Performance Package
Prompts the selection of the HPP version of the HyPET machine and robot. HyPET HPP
●
includes enhancements such as faster and smoother performance as well as improved part-to-
part consistency.

C8591 – Standalone Dehumidification for High Performance Package

○
Provides the molding area dehumidification unit and the CoolPik blower unit.

C8592 – High Performance Blower for Centrally Dehumidified Plant Package

○ Provides the CoolPik air blower unit. The customer will supply the dehumidified air to the molding
area in the machine robot.

C8593 – Standalone Dehumidification for High Performance Package - High Temperature Application
Provides the molding area dehumidification unit and the CoolPik blower unit. The High
○
temperature package is recommended where ambient conditions are expected to exceed 32°C
Dry Bulb temp and/or 25°C Wet Bulb for more than 3 days/year.

Notes:
- Some plants in high temperature locations are air conditioned hence would only require the standard package
C8591 as ambient conditions around the machine would be below the threshold indicated.
- At least one of the option C8591,C8592 or C8593 has to be selected for HyPET HPP machines.

● Standard feature
○ Optional feature

Version 9.11 — May 2011

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Features and Options

Dehumidification Enclosure Feed throat Magnet

Walkway Audible Alarm

Convenience Outlet Package Control Outlet for mixer/blender

Version 9.11 — May 2011

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Features and Options

Optical Part Detection

Machine Nozzle Remixer

Two-Piece Cavities

Version 9.11 — May 2011

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Thread Specifications

PL
PLK

Version 9.11 — May 2011

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HUSKY, HUSKY KEEPING OUR CUSTOMERS IN THE LEAD are registered trade-marks of Husky Injection Molding Systems Ltd. in the United
States and other countries, and may be used by certain of its affiliated companies under license. Other HUSKY product or service names or logos
referenced in these materials are trade-marks of Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies under
License.

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