Polymers

for
Blow Moulded Containers

By
Dr Jitendra N Kapadia
Product Application & Research Centre
Reliance Industries Ltd
Mumbai.
BLOW MOULDING PROCESS
Blow molding is a process for manufacturing hollow articles.
In blow molding air is blown through a tube of hot plastic,
pushing the material outwards to the side of the mold.

Types of Blow Moulding

• Extrusion blow moulding - Continuous type and
Intermittent type
• Injection blow moulding
• Extrusion stretch blow moulding
• Injection stretch blow moulding
BLOW MOULDING PROCESS
BLOW MOULDS
Material of Construction :

Mild Alloy Steel

Aluminium

Beryllium Copper
 BLOW MOULDS :
ESSENTIAL REQUIREMENTS
• Adequate cooling, preferably along the contours of the
cavity

• Cooling of thicker areas, articles like neck, top and

bottom pinch-offs

• Proper alignment of the two halves

• Sandblast finish for moulds of 5 litres and above of 40 /

50 mesh grit - to avoid entrapment of air.
 KEY RESIN PARAMETERS
• Melt Flow Index

• Density

• Molecular Weight Distribution

• Melt Swell

• Pinch-off

• Pigments / Additives
 MATERIAL
PROPERTY REQUIREMENTS
• High melt strength to resist sag during parison formation.
( Low MFI resin)

• Low ‘high shear viscosity’ - lower load and faster

extrusion rate without melt fracture. (Broad MWD resin)

• Consistent melt swell, moulds designed to accommodate

a particular shape of parison.
 MOLDED ARTICLE
PROPERTY REQUIREMENTS

• Adequate stiffness to prevent buckling of containers during

stacking. (High Density )

• Adequate drop impact strength.

• Resistance to environmental stress cracking.

• Good barrier to gases and liquids

 MELT SWELL : DIAMETER
AND WEIGHT

Weight swell= weight of actual parison – weight of theoritical parison x 100%

weight of theoritical parison

Diameter Swell = diameter of actual parison – diameter of die x 100%

diameter of die
 IMPORTANCE OF MELT
SWELL
• Resins manufactured by different processes differ in
their swelling characteristics.

• When extruded through the die, they are forced to uncoil

and stretch in the flow direction.

• On emergence, these relax to their random orientation,

causing parison swell.
 IMPORTANCE OF MELT SWELL
• Swell can be adjusted by modifying processing
characteristics like temperatures and screw speed.

• Change in the tooling dimension (cup and mandrel

size)
 EFFECT OF VARIOUS TYPES OF
TOOLING ON MELT SWELL
Two basic types of tooling are generally used

 Divergent Tooling :
A divergent tooling is generally
preferred for larger articles.
It gives greater thickness swell
as compared to diameter swell.

 Convergent Tooling :
A convergent tooling is generally preferred for smaller
articles. It gives greater diameter swell as compared to
thickness swell.
EFFECT OF VARIOUS TYPES OF
TOOLING ON MELT SWELL
Parison Sag
Causes –
 Action of gravity
 Very long parisons
 Parison drop time

Remedy -
Parison Programmers
 PINCH-OFF
DESIGN/STRENGTH
• Pinch-off design plays an important role in container
performance during drop-test.

• Pinch-off design determines weld section strength of a

container.

• Section has to be designed carefully to get better seal

strength.
 PINCH-OFF
DESIGN/STRENGTH
• Pinch-off should not be sharp but land of about 0.5
to 3.0 mm

• Angle of the pinch-off to be acute to provide smooth even

finish on the outer surface and slightly raised surface on
the inner side.

• When pinch-off is too deep or when flash pockets are too

deep (for articles with handles) more quantity of parison is
gripped within the flash pocket which results in weaker
seals and container failure in drop test.
PINCH-OFF DESIGN/STRENGTH

Type of pinch-off recommended A well-designed pinch-off

Location of pinch-off area Unacceptable pinch-off

 Extrusion Blow Moulding;
Disadvantages
 The dimensions of the parision is always greater than the
diameter of the die due to die swell phenomena.
 There may be deformaties due to flow defects.
 Since the machine extrudues the material vertically
downwards, during the delay between extrusion and
inflation the weight of the parision causes sagging.
 There is a pressure gradient along the flow direction.
 There is also a pressure gradient along the perpendicular
to flow direction.
IBM Applications
 Dropper bottles
 Injectables
 Tablets and Pill bottles
 Baby bottles
 Bellows
 Light globes
 Flower bases and bowls
 Testing
 Testing can be divided in to two parts :

Quality Control : Testing of incoming

raw materials

Quality Assurance : Testing of finished

products
 Testing Procedures….
 Quality Control on plastic raw materials

• Melt Flow Index

• Notched Izod Impact
• Flexural Modulus

 Quality Assurance of finished product

• Stacking Test
• Test for drop impact strength
• Test for closure effectiveness
• ESCR tests
• Vibration tests
• Storage tests
• Test for ink adhesion of printed container
• Test for product resistance of printed containers
 H
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 EFFECT OF MOLECULAR WEIGHT (MFI),
MOLECULAR WEIGHT DISTRIBUTION (MWD)
& DENSITY ON PROPERTIES OF HDPE

Property MFI Increasing MWD Broadening Increasing Density

Melt Strength  
Melt Viscosity  
Impact Strength   
Stiffness 
ESCR   
Chemical Resistance 
Hardness 
Permeability 
APPLICATIONS OF HDPE
 Edible oil
 Chemicals
 Petro Products (Lube Oil)
 Pharmaceuticals
 Pesticides
 Cosmetics
 Toys
 Automotive Parts (Arm rest, windshield washer
bottle)
APPLICATIONS OF POLYETHYLENE

Bottles Edible Oil Containers

Milk Bottles

Pesticide Containers Lube Oil Containers

 RELIANCE GRADE CHART FOR
RELENE HDPE

Grade Density MFI MWD Typical Applications

(g/cm3) (dg/min)

EB - 16 0.951 0.27 Broad 5 lt & above lube oil containers.

F46003 0.946 0.30 Broad Detergent bottles,

pesticide containers

B56003 0.956 0.30 Broad Oil bottles, Jerry cans,.

PROCESSING OF HDPE
 Extrusion Temperatures :
– Melt temperatures in the range of 175 - 205ºC are
recommended.
– Normally, temperatures of s190 - 205ºC will result in
optimum ESCR properties.
– No premium in stress crack resistance can be
expected by increasing melt temperatures above
215ºC.
 Mould Temperatures :
– Mould temperatures should be preferably 20ºC to
minimize cycle time. The cycle time also depends upon
mould design and atmospheric conditions.
– Mould temperatures should not be too low as this
would lead to mould sweating.
 Applications…
 Drums and canisters
 The manufacturing of industrial containers – drums, canisters, IBC’s requires
polymers with high melt strength, high stiffness and creep resistance,
outstanding impact properties and excellent resistance to chemicals and
stress cracking (ESCR).
 This particular property profile is achieved through a particular combination of
catalyst systems, polymerisation technology, polymer parameters and
additives.
Multilayer Applications
Multilayer bottles for food packaging (cold filled):
The typical complex structure is based on LDPE or HDPE. HDPE
is used for its rigidity and LDPE for its softness (squeezable).
High barrier to oxygen, gas and aroma is provided by an EVOH
layer.

Examples of applications: mustard bottles , sauces, fruit juice

bottles ( long life ) ...
Multilayer Application…
Multilayer bottles for food packaging (hot filled):
The typical complex structure is based on PP.
High barrier to oxygen, gas and aroma is provided by an
EVOH layer.

Examples of applications: Ketchup bottles , Hot filled juice

(fruit, food...)
PP O
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 Polypropylene …
• Polypropylene is a naturally translucent material which provides
contact clarity and an excellent moisture barrier.
• PP is easily processed via injection molding (jars and closures),
and injection, extrusion, or stretch blow-molding (bottles).
• One major advantage of polypropylene is its stability at high
temperatures, up to 200° F. Polypropylene is autoclavable and
offers the potential for steam sterilization.
• PP has excellent chemical resistance, but provides poor impact
resistance in cold temperatures.
• Oriented PP offers improved impact resistance and clarity at low
temperatures.
• Produced in color, PP exhibits a glossy finish.
 Polypropylene …
 The three main types of polypropylene produced and marketed by
Reliance are:

· Homopolymers, which have high heat resistance and good

rigidity, making them suitable for a vast range of applications;

· Copolymers, which are made by incorporating different

monomers, are extremely resilient materials and have wide uses
in automotive and industrial applications; and

· Random copolymers, which are made by introducing ethylene

links into the polymer chain, tend to have improved optical
properties, making them ideal for applications such as packaging
where transparency is required.
 APPLICATIONS OF
POLYPROPYLENE
Bottles and containers for :

 Mineral water
 Cough syrup
 Sterile fluid
 Syrup & Squash
 Mouthwash
 Lotion
 Cream
 Baby feeding bottle
 Shampoo
 Face powder
 Tooth powder
 Ketchup
APPLICATIONS OF POLYPROPYLENE

Oral care products Shampoo bottles

Skin care products Food applications

Large water
containers
 POLYPROPYLENE
Properties of PP which make it an ideal blow
moulding material are :
 Very low density
 High stiffness
 High surface hardness
 Very good chemical resistance & ESCR
 Contact clarity & gloss
 Very low water absorption & transmission
 Good resistance to high temperature
 Elastomer modified grades have very good toughens
at low temperatures
 Ideal for smaller containers
 RELIANCE PP GRADES FOR BLOW
MOULDING

Grade Type MFI Special Characteristics

(dg/min)

H007EG Homopolymer 0.7 Good rigidity

H020EG Homopolymer 2.0 Good rigidity and processability

R019MG Random 1.9 Without clarifier for

Copolymer Medical applications.
R019MZ Random 1.9 Low odour, contains
Copolymer clarifier
C015EG Impact 1.5 High impact copolymer
Copolymer
GUIDELINES FOR PROCESSING PP

 For blow moulding applications, PP with MFI between 1 to

3 dg/min. should be used.
 Screw with L/D > 20 and compression ratio > 2 should be
used
 Melt temperature should be between 180 & 220°C
 Adequate venting of mould is required for good container
surface finish
 Hot wire cutter should be used for parison transfer
 Adequate mould cooling for faster cycles and better clarity
PP O
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PVC
Characteristics of PVC which leads to its use

in bottles include :
 Clarity

 Chemical resistance

 Shatter resistance

 Rigidity

 Light weight
GUIDELINES FOR PROCESSING
PVC
 Melt temperatures should be between 180 - 200°C
 Screw and head system should be purged with PE during
shut down
 Poorly stabilised PVC bottle compound evolves HCl.
Hence,
– Nitrided screws and barrels should be used
– Tapered screw with compression ratio 1.8 : 1 is to be
used
– Streamlined design of head and die. Chrome plated
moulds are required
APPLICATIONS OF PVC
 Household Products  Fabric Softners, Stain
Removers, Bleach, Linseed
Oil, Machine Oil, Window
Cleaner
 Cosmetics & Toiletries

 Oils, Lotions, Shampoos,

Creams, Hair Dye, Face
 Industrial Chemicals Powder
 Auto Antifreeze, Brake Fluid,
Fuel Oil, Furniture Polish,
Photographic Chemicals
 Food & Beverages
 Juices, Instant Cocoa, Edible
Oil, Jam, Liquors, Tea
Leaves, Vinegar
APPLICATIONS OF POLYVINYL
CHLORIDE

PVC Containers
Food Containers

Water Containers Hair Oil Containers

PVC RESIN SPECIFICATIONS FOR
BLOW MOULDING

 K-Value  57 + 1

 Heat Loss  0.3% max.

 Particle Size  100 - 130 micron

 Porosity  0.22 - 0.28 ml/g of DOP

 Bulk Density  0.49 - 0.55 g/ml

 Residual VCM  1 ppm max.

 PVC COMPOUND FOR BLOW
MOULDED BOTTLES
 PVC has low thermal stability, hence it needs to be compounded with
different additives before processing.

PVC COMPOUND EXTRUSION BLOW MOULDING

Resin 100
Heat Stabiliser 2 phr
Epoxidised soya oil 3 phr
Int. lube - GMS 0.3 phr
Ext. lube - OP wax 0.1 phr
Processing aid 0.5 phr
Impact Modifier 7 - 10 phr
Optical Whitener 0.005 phr

 Formulation of PVC resin varies with type of resin, machine used,

product design, size and end properties requirement of product. It has
to be tailoured to optimise all the variables
PREPARATION OF PVC BOTTLE
COMPOUND
 Start the mixer at low speed
 Add stabiliser (primary & secondary)
 Increase speed
 At 65°C, add impact modifier
 At 90°C, add lubricant
 At 95°C, add optical whitener
 At 105°C, add processing aid
 At 110 - 115°C, discharge at high speed into cooler
mixer
 Cool in cooler mixer upto 40°C
 Discharge
 BLOW MOULDING OF PVC

 PVC blow moulding grades must have the following

requirements :

– Low K value for easy processing

– Low fish eyes / gels

– Uniform particle size

 RIL’s PVC blow moulding grade 57-11 is used for rigid

bottles
 PP OO LL YY EE TT HH YY LL EE N
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(( PP EE TT ))
A Versatile Bottle Grade Polymer
A Versatile Bottle Grade Polymer
MANUFACTURING PROCESS

PET - 1 MT
PTA -0.85 MT
base chips of
+
~ 0.62 IV
MEG - 0.35 MT
Condensation Polymerization

Copolymer- IPA PET BOTTLE GRADE RESIN

Catalyst - Antimony based Base chips subjected to Solid State
Additives - Toners , Polymerization to raise IV level to
Heat Stabilizers , DEG ~ 0.72 to 0.84 dl/g
 PET COPOLYMERS
 PET produced in two forms

– Homopolymer (PTA and MEG).

– Copolymer (PTA, MEG and IPA).
 Copolymers have

– Lower melting point.

– Lower crystallization rate.
– Better formability.
– Better ESCR particularly under humid and tropical
conditions.

Copolymers are predominantly used for bottle application .

 RESIN CHARACTERISTICS
 Intrinsic Viscosity (I.V.) :
Measures Average length of molecular chains or
molecular weight .
Determines mechanical performance of bottles.
Common I.V. range for bottles is 0.72 - 0.84.

 Acetaldehyde (AA) Content :

Produced as a byproduct of thermal degradation during
melt-phase polymerization and gets entrapped in the
polymer. Has a boiling point of 21°C with a fruity odor.
Can influence taste of packed products esp. MW
AA content is maintained below 1 PPM in the resin.
AA is further generated during conversion of PET resin
into preforms.
 RESIN CHARACTERISTICS
 Glass-Transition Temperature (Tg) :
Temperature at which amorphous polymer softens and
becomes rubbery.
Tg of PET is between 75 and 85°C.
Amorphous PET can be stretched mechanically at
temperatures above Tg to orient molecular chains in one
or two directions.

 DEG Content :
Maintained around 2% for homopolymer and around 1%
for copolymers.
Influences melting point, crystallization rate and melt
viscosity.
 RESIN CHARACTERISTICS
 Color / “b” value :
Should be as close to neutral ( 0 ) as possible.
Bluish tinge is preferred to yellowness.

 Crystallinity :
Should be >50% to avoid softening and agglomeration of
chips during drying.
Crystallinity is directly related to density.

 Crystalline Melting Point (Tm) :

PET homopolymers - 252°C and PET copolymers -
247°C.
 RELPET RESIN GRADE CHART
PROPERTY UNIT G5761 G5801 G5841
Intrinsic Dl /g 0.76 + 0.02 0.80 + 0.02 0.84 + 0.02
Viscosity (I.V)
Acetaldehyde ppm 1.0 max 1.0 max 1.0 max
(AA)
DEG Content % w/w 1.4 1.4 1.4
Crystalline G / cc 1.39 min 1.39 min 1.39 min
Density
Colour ‘b’ value CIE 0 to –2.0 0 to –2.0 0 to –2.0
0
Crystalline C ~ 247 ~ 247 ~ 247
Melting Point
Crystallinity % >50 >50 >50
Chips Weight g 1.25 – 1.75 1.25 – 1.75 1.25 – 1.75
(100 chips)
Fines ppm 100 max 100 max 100 max
Applications Water , Edible General CSD , Agrochemical ,
Oil , Small Jars Purpose Strapping
, Sheet
 GLOBAL FOOD CONTACT
APPROVING BODIES
 Accorded based on migration studies carried
out on bottles by a recognised testing
laboratory
 Two Regulations are accepted globally
– USFDA Regulation No. 177.1630
– EU Regulation No. 90/128/EEC
 END USER APPROVALS
 End-use industries such as manufacturers of soft drinks
and mineral water accord their own approval based on
the tests designed specifically for their products.
 Examples
CSD MINERAL WATER
Carbonation Loss AA Content
Creep Resistance Taste Variation
Stress Cracking Aldehydes Migration
Bottle Roll Out
 PET DOWNSTREAM
PROCESSING
DEHUMIDIFIER
PET DRYER
AUTOLOADER 170 degC
RESIN
4 hours

PET
PREFORMS
CHILLER

INJECTION
INJECTION MOLDING
MOLTEN PET
MOULD -chill 270 degC
at ~ 12 degC

PREFORM INJECTION MOULDING PROCESS

PREFORM
STRETCH BLOW PROCESS
S
P T

R HEATER
CONDITIONING R
~80 degC to make E
E preform soft T
C
F H
COMPRESSOR
O
R
M
BOTTLE BLOW
MOULD

FROM PREFORM TO BOTTLE

 RESIN TO BOTTLE

PREFORM STRETCH - BOTTLE

BLOW
PET BOTTLE
 DOWNSTREAM PROCESSING -
SINGLE STAGE vs. TWO STAGE

 SINGLE STAGE PROCESS:

INJECTION MOULDING + STRETCH BLOW
MOULDING TAKES PLACE ON SAME MACHINE

 TWO STAGE PROCESS:

INJECTION MOULDING AND STRETCH BLOW
MOULDING IS DONE ON SEPARATE MACHINES
 SINGLE STAGE PROCESS -
APPLICATIONS
• Pharmaceutical bottles
• Liquor bottles
• Jars
• Extended to “ Untouched by hand “
• Low Volumes - Small Transportation
distance type businesses
 TWO STAGE PROCESS -
APPLICATIONS
• Carbonated Soft Drinks
• Mineral Water
• Juices
• Beer
• High Volume - High Transport distance type of
business
• Preform Unit at one location and Blowing at “
Satellite Locations” - which are in vicinity to the
End-user
PET BOTTLES - VARIED
APPLICATIONS
PHARMACEUTICAL BOTTLES
HOT FILL BOTTLE
20 LTR PET CONTAINER
 MARKET OPPORTUNITIES -
RIGID CONTAINERS OF PET
• BEER

• ACTIS Technology from Sidel a success -

Amorphous Carbon Treatment on Internal Surface
• Rapid ACTIS Technology implementation in Europe ,
China
• Untapped opportunity in India
• Liberal Beer policy in U.P. a big boost to Beer
consumption
 MARKET OPPORTUNITIES -
RIGID CONTAINERS OF PET
• AERATED WATER ( SODA ) :

• Small Bottled Water producers diversification into “Pet

Soda “
• Preform quality is critical for good standing bottle -
uniform wall thickness , short length
• Good quality preform availability is lacking for soda -
hindrance to growth
• Punjab , A.P. are largest soda markets in India