Extrusion Blow Research Articles

Mechanical and Tribological Characterization of Microporous Low Density Polyethylene Films Obtained in Blown Extrusion

Mechanical and Tribological Characterization of Microporous Low Density Polyethylene Films Obtained in Blown Extrusion

Pengaruh Motivasi Kerja dan Disiplin Kerja terhadap Kinerja Karyawan Extrusion Blow PT. Jayatama Selaras

The purpose of this quantitative research is to analyze the extent to which motivation and discipline influence the performance of PT. Jayatama Selaras Extrusion Blow employees. The data collection method applies a questionnaire distributed to respondents. Researchers in this research use quantitative analysis such as validity and reliability tests, classical assumption tests, multiple linear regression analysis, hypothesis testing, and determination coefficient tests. All of these analyses were conducted using SPSS version 25. This study involved all PT. Jayatama Selaras Extrusion Blow employees, totaling 50 respondents. The saturated sample method was used to determine the sample. The results showed that with a regression coefficient of 2.145 ≥ 1.677, motivation partially has a significant effect on employee performance. With a regression coefficient of 12.914 ≥ 1.677 discipline partially has a significant effect on employee performance. It is shown that simultaneously motivation and discipline have a significant effect on employee performance, F count 256.961 ≥ F table 3.195, and the significance value of each variable ≤ 0.05. The coefficient of determination test proves that motivation and discipline influence employee performance by 95.7%, while 4.3% are factors that are not involved in this research.

PLA/PBAT blends for blown film extrusion

Films of biodegradable PLA/PBAT blends with PBAT content of 10–90 wt% were obtained by extrusion blowing. PLA/PBAT blends were characterized by FT-IR, DSC, TGA and SEM. Tensile properties and tear strength of the films were also determined. It was shown that despite thermodynamicimmiscibility of PLA and PBAT, addition of PBAT in amounts above 50 wt% allows obtaining films with good functional properties. Optimal properties were obtained with PBAT content of 60 or 70 wt%. Tensile strength was 36.7–38.7 MPa, elongation at break 357–388% and tear strength 11–22 N/mm.

Analysis of Extrusion Blow Molding Machine Maintenance Planning with Reliability Centered Maintenance and IRRO Method

High demand for plastic products from year to year creates the need for plastic molding machines that can mass produce plastic products. An example of a plastic molding machine used at PT. X is a VK type extrusion blow molding (EBM) machine. Based on data from PT. X, the downtime of the VK type EBM machine reached 215.74 hours in 2021-2023. Therefore, improvements are needed in the machine maintenance management system. The purpose of this research is to determine the critical components, determine the reliability value of the critical components, and also establish a preventive maintenance schedule along with a cost budget plan for each critical component of the VK type extrusion blow molding machine at PT. X to increase the effectiveness of existing production activities. The method used is Reliability Centered Maintenance (RCM) with the application of RCA and FMEA methods to find critical components, then calculate the reliability of critical components as a reference for making preventive maintenance schedules. The data used are the failure data of VK type EBM machine in 2021-2023 period. The results of this study obtained 4 critical components with a reliability value of 0.5, namely the clamping unit at 210.3149 hours, the cutting unit at 79.9911 hours, the head unit at 677.5324 hours, and the hydraulic unit at 424.1550 hours. Maintenance planning is based on the IRRO (Inspection, Repair, Replace, Overhaul) method. The total maintenance cost for the period 2025 is Rp 35,093,903, which reduces the cost by 8.5% compared to 2023.

Malt bagasse in extruded wheat flour and PBAT biodegradable films

Malt bagasse (BM) is a byproduct of the brewing industry with low added value but is rich in fiber and proteins, making it a potential product to be incorporated into the formulation of biodegradable films. This work aimed to produce biodegradable films based on wheat flour and PBAT added with different concentrations of BM (0 – 7.5 %) by blown extrusion. The films were characterized by physical, optical, morphological, thermal properties, and compostability. It was possible to produce biodegradable films by blown extrusion with excellent processability. BM increased film opacity with a heterogeneous, rough, and yellowish surface. Also, BM addition in the films reduced their hydrophilicity; however, as the BM concentration increased, there was a reduction in the elongation at break, tensile strength, and thermal stability of the films. The film with 7.5 % BM showed greater fragmentation and mass loss during the composting process, possibly due to the fragile matrix that facilitated the action and degradation by microorganisms. The biodegradable films containing BM are viable alternative for packaging production for different products.

Extending the Finite Area Method for enhanced simulation of deformable membranes and its application to extrusion blow moulding

This paper investigates the mechanics of the Extrusion Blow Moulding (EBM) process, focusing on the clamp and inflation phases. The simulation framework employed in this study has been developed using OpenFOAM ® and extends the available Finite Area Method with a vertex-centred approach. This cutting-edge developments integrated a corotational formulation with a quasi-static approximation. The computational code and algorithm are verified and validated through comparisons between analytical solutions, experimental measurements and simulation results, ensuring the accuracy and reliability of the proposed approach. The implemented code is verified by checking fundamental principles of hyperelastic materials behaviour, demonstrated through equibiaxial deformation of spherical balloons. The use of neo-Hookean and Mooney–Rivlin material models provides crucial insights into material responses under different inflation conditions. The studies begin employing a conceptual mould within the EBM process that allows examining the effects of mould clamping on parison deformation. Then the study extends to analysing a real bottle manufactured via EBM, employing Stereolithography (STL) digitization and thickness mapping to quantify the thickness distribution. The simulation results closely replicates experimental observations, capturing the inherent non-linearity of these process stages, including large deformations and displacements, hyperelasticity and parison-mould contacts. This interdisciplinary research enhances understanding of the EBM process phases and analogous processes, providing valuable insights for plastic manufacturing. It improves the design process for meeting specific requirements and offers guidelines to avoid potential failures. The findings underscore the importance of such studies in advancing sustainable and efficient plastic manufacturing practices, with applications ranging from inflatable structures to EBM processes.

Poly(butylene adipate-co-terephthalate)/thermoplastic canna starch (Canna edulis ker.) (PBAT/TPS) blend film – A novel biodegradable material

The PBAT (poly (butylene adipate-co-terephthalate) is a promising biodegradable material. However, it is often blend with hydrophilic polymers since its degradation rate in the aquatic environment is still limited. In this study, the blend PBAT/TPS (thermoplastic starch) films, namely BFs, were prepared by a blow extrusion approach, and evaluated for hydrolysis in four studied mediums acid (HCl, 1 M, 2 M, and 3 M), alkaline (NaOH, pH = 9, 11, and 13), phosphate buffer (pH = 7.4), and artificial seawater. The hydrolyzed BFs were characterized by weight loss, mechanical properties, scanning electron microscopy (SEM), Fourier transform infrared spectra (FTIR), and differential scanning calorimetry (DSC). A larger starch content in the BFs caused hydrolysis more quickly. The highest hydrolytic rate was found in the alkaline solution, followed by the acid medium. The complete abiotic hydrolysis of the BFs was 3 M HCl for 14 days or NaOH (pH 13) for 35 days. After 180 days of incubation, the film containing 70.5 % PBAT/TPS granules has been associated with the highest biodegradation rate of 76.31 % in composting.

Feasibility study on the production of low melt flow rate recycled polypropylene from postconsumer waste

AbstractPolypropylene (PP) recyclates face limitations in their use due to lower qualities compared with virgin PP, resulting from contaminations and the mixing of different PP grades. In particular, their high melt flow rate (MFR) hinders their suitability for applications requiring low MFR, such as pipes. This study investigates the feasibility of producing low MFR PP recyclates from packaging waste. For this purpose, recyclates were produced exclusively from manually sorted extrusion blow molding grades and compared with a recyclate derived from a conventional PP waste stream. Different washing temperatures and recyclate production processes were used to study their effects on the properties of the recyclates. The main objective was to determine the lowest achievable MFR and the rheological, mechanical, and thermal properties of the recyclates from improved sorting. The results are intended to serve as reference points for the evaluation of future automatic sorting trials. The enhanced sorting resulted in an 80% reduction in the MFR and improved ductility, thereby extending the potential applications of the recyclate. The different washing and production processes did not have a significant effect on the investigated properties, except for a slight decrease in the MFR with hot washing and the omission of the pelletizing step.

A biodegradable pH-response packaging film with blueberry extract: Blown-extrusion fabrication, multifunctional activity, and kinetic investigation

This work proposed a novel strategy for manufacturing biodegradable pH-response packaging. Briefly, to minimize the amount and thermal processing times of blueberry extract (BE), ethanol-dissolved BE (≤ 3‰ w/w) was sprayed onto the starch/poly(butylene adipate-co-terephthalate) (PBAT) pellets before extrusion blowing. BE was well-integrated into the matrix, forming uniformly colored films. The films with BE exhibited superior mechanical (7.85 MPa of strength, 606.53% of elongation) and enhanced barrier capabilities against ultraviolet light, moisture, and gas. Additionally, they exhibited good antioxidant capacity (68.69%), antibacterial activity (72.40%), and maintained color stability. The film with 3‰ w/w BE presented excellent color responsiveness (ΔE⁎ ≥ 15) in the alkaline range, and successfully monitored the spoilage of shrimp. The pigments in the film had the maximum migration degree (≥ 70%) and rate in 50% ethanol simulation, following a first-order kinetic behavior dominated by Fickian diffusion. Findings supported the application of this strategy in the fabrication of starch/PBAT/BE films for pH-response intelligent packaging.

A data-driven analysis of HDPE post-consumer recyclate for sustainable bottle packaging

The packaging industry faces mounting demand to integrate post-consumer recyclate (PCR). However, the complex structure-property relationships of PCRs often obscure their performance compared to virgin equivalents, posing challenges in selecting suitable PCRs for applications. Focused on extrusion blow moulding grade high-density polyethylene (HDPE), this study presents the most extensive characterisation of HDPE PCR to date, encompassing 23 resins (3 virgin, 20 PCR). Employing Fourier-transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), rheology, colour analysis, and mechanical testing, we established a feature-rich dataset with 56 distinctive characteristics. Utilising a data science approach based on principal component analysis, with the virgin samples as a benchmark, we identified that combining FTIR, TGA and mechanical testing provided effective identification of PCRs that closely match the properties of virgin HDPE. The pipeline created can be utilised for new PCRs to determine suitability as a replacement for virgin plastic in a desired application.

Mechanical activation-enhanced metal-organic coordination strategy to fabricate high-performance starch/polyvinyl alcohol films by extrusion blowing

The production of high-performance starch-based packaging films by extrusion blowing is challenging, ascribed to poor processability of the blend precursors. In this study, a new strategy of mechanical activation (MA)-enhanced metal-organic coordination was proposed to improve the processability of starch (St)/polyvinyl alcohol (PVA) blend precursor, with calcium acetate (CA) as a chelating agent and glycerol as a plasticizer. MA pretreatment activated the hydroxyl groups of starch and PVA for constructing strong metal-organic coordination between CA and St/PVA during reactive extrusion, which effectively enhanced the melt processing properties of the blend precursor, contributing to the fabrication of high-performance St/PVA films by the extrusion-blowing method. The as-prepared St/PVA films exhibited excellent mechanical properties (tensile strength of 34.5 MPa; elongation at break of 271.8 %), water vapor barrier performance (water vapor permeability of 0.704 × 10−12 g·cm−1·s−1·Pa−1), and oxygen barrier performance (oxygen transmission rate of 0.7 cm3/(m2·day·bar)), along with high transmittance and good uniformity. These outstanding characteristics and performances can be attributed to the improved interfacial interaction and compatibility between the two matrix phases. This study uncovers the mechanism of MA-enhanced metal-organic coordination for improving the properties of starch-based films, which provides a convenient and eco-friendly technology for the preparation of high-performance biodegradable films.

Active Low-Density Polyethylene-Based Films by Incorporating α-Tocopherol in the Free State and Loaded in PLA Nanoparticles: A Comparative Study

In this work, alpha-tocopherol (α-TOC) was encapsulated in poly(lactic acid) nanoparticles (PLA NPs) and added to low-density polyethylene (LDPE) films with the aim of producing an active film for food packaging applications. PLA NPs loaded with α-TOC were produced through nanoprecipitation and dried using two methods (freeze-dryer and oven). LDPE-based films with final polymeric matrix concentrations of 10 and 20 g/kg were then produced through blow extrusion. The results showed that LDPE-based films loaded with α-TOC can be produced using blow extrusion, and a good distribution of PLA NPs can be obtained within the LDPE matrix as observed using scanning electron microscopy (SEM). The mechanical properties were affected by the incorporation of α-TOC and PLA NPs loaded with α-TOC, with the observation of a decrease in tensile strength and Young’s Modulus values and an increase in elongation at break. Regarding water vapor permeability, the films showed a reduction in the values with the addition of α-TOC and PLA NPs loaded with α-TOC compared to the LDPE film (control). Films with α-TOC in the free state and loaded in PLA NPs showed antioxidant activity, but their behavior was affected by the encapsulation process.

Tailored biodegradable films via extrusion blow molding using PBS, PBAT, and TPS

AbstractResearch to replace synthetic polymers with biodegradable polymers is on the rise because common plastics have generated serious ecosystem problems. Films with thermoplastic starch (TPS), poly(butylene succinate) (PBS), poly(butylene adipate‐co‐butylene terephthalate (PBAT), and citric acid (CA) were produced by blown extrusion. They were characterized by blow‐up ratio (BUR), water vapor permeability (WVP), soluble ratio (SR), water sorption isotherm, and thermogravimetric (TG) techniques. Films were uniform and showed BUR > 205%. The different proportions of PBS and PBAT significantly influenced the WVP of the films. All samples had WVP with an order of magnitude similar to other blends with high starch content (10−6 g m−1 day−1 Pa−1). CA efficiently decreased the WVP of the PBS/PBAT/TPS formulations (15/15/70% and 20/10/70% by mass) by 25.2% and 24.7% compared to the acid‐free formulations. There was no significant difference in SR (19.0%–20.1%). These materials were sensitive to moisture since the equilibrium moisture content increased pronouncedly from water activity of 0.5. Films showed good thermal stability, with a maximum decomposition temperature close to pure polyesters. CA did not increase the thermal stability of blends, probably because of the low content used (0.1%). Given the outcomes of this study, these films could be deemed appropriate for applications in food packaging.

Design and fabrication of bio-based functional composite materials with antibacterial, antioxidant, and improved mechanical properties based on poly (butylene adipate-co-terephthalate) (PBAT) for food packaging

The PBAT/epoxy chain extender (ADR-4468) film, with its competitive pricing, excellent biodegradability, and outstanding mechanical properties, stands out. Through experimental design, quercetin (QR) with antibacterial and antioxidant properties was effectively grafted onto the epoxy chain extender (ADR-4468), resulting in the successful synthesis of the functional modifier A-QR. PBAT composite films containing different weight percentages (0.2, 0.4, 0.6, 0.8, and 1% w/w) of A-QR were prepared using extrusion blow molding technology. QR and ADR are chemically bonded together, forming a strong and tightly knit composite. The composites exhibit excellent composite effects and outperform single-component blends, reducing A-QR migration, improving mechanical properties, and enhancing the barrier properties of the composite film. Structural, mechanical, and water barrier properties, antibacterial and antioxidant properties, as well as freshness preservation effects of the film, were analyzed. A-QR and PBAT formed a cross-linked network structure through chain extension reactions. Tensile strength increased from 19.7 MPa to 37.9 MPa, representing a 92.4% improvement. Antioxidant activity reached up to 65%. It exhibited excellent antibacterial activity against Staphylococcus aureus and Escherichia coli. The maximum total migration was only 0.7 mg/dm2, significantly below the specified overall migration limit (OML). PBAT/A-QR films successfully extended the shelf life of bananas, strawberries, apples, and oyster mushrooms due to their excellent antioxidant, antibacterial, and water barrier properties.

Extrusion-blown oxidized starch/poly(butylene adipate-co-terephthalate) biodegradable active films with adequate material properties and antimicrobial activities for chilled pork preservation

Food safety concerns from spoilage and non-degradable packaging risk human health. Progress made in biodegradable plastic films, but limited study on biomass composite films with favorable morphological, mechanical, and inherent antibacterial properties for fresh meat preservation. Herein, we present a versatile packaging film created through the extrusion blowing process, combining oxidized starch (OST) with poly(butylene adipate-co-terephthalate) (PBAT). SEM analysis revealed even distribution of spherical OST particles on film's surface. FTIR spectra revealed new intermolecular hydrogen bonds between OST and PBAT. While combining OST slightly reduced tensile properties, all composite films met the required strength of 16.5 ± 1.39 MPa. Notably, films with 40 % OST showed over 98 % antibacterial rate against Staphylococcus aureus within 2 h. pH wasn't the main cause of bacterial growth inhibition; OST hindered growth by interfering with nutrient absorption and metabolism due to its carboxyl groups. Additionally, OST disrupted bacterial membrane integrity and cytoplasmic membrane potential. Remarkably, the OST/PBAT film excellently preserved chilled fresh pork, maintaining TVB-N level at 12.6 mg/100 g on day 6, microbial count at 105 CFU/g within 6–10 days, and sensory properties for 8 days. It extended pork's shelf life by two days compared to polyethylene film, suggesting an alternative to a synthetic material.

Improving the performance of post-consumer resin feedstocks for rigid packaging applications: A pilot-scale assessment

Various market, environmental and political drivers encourage the use of more post-consumer resin (PCR) high-density polyethylene (HDPE) in rigid packaging. However, PCR HDPE performs poorly compared to virgin HDPE, particularly in blow-moulded bottles for cleaning products which often show inadequate resistance to environmental stress cracking. In this study we evaluate and compare additives representing various strategies designed to improve the mechanical performance of PCR HDPE. Two commercially available recycled HDPE PCRs were extruded with eight candidate additives and the bottle performance of the best performing blends were tested in extrusion blow moulding trials. FTIR analysis revealed polypropylene contamination in one PCR although rheology and thermal properties were very similar. The use of strain hardening modulus as a selection criterion for pilot scale trials was demonstrated. The results revealed that particulate additives may have negative effects while polyolefin additives are more likely to succeed at the pilot scale.

Experimental Investigation and Optimization of Blow Molding Process Parameters of HDPE Material

Abstract: Optimization of machining processes is essential for achieving higher productivity and high-quality products in order to remain competitive. The objective of this study is to optimize the process parameter of extrusion blow molding process of high density polyethylene (HDPE). In this paper three process parameters namely barrel temperature, Mandrel Position, Screw Rotation. Taguchi Method is a statistical method to improve the process parameters and improve the quality of components that are manufactured. ANOVA has been carried out to identify importance of the operating parameters on the performance characteristics considered. Further the verification experiment has been carried out to confirm the performance of optimum parameters. The results from this study will be useful for selecting appropriate set of process parameters to epoxy coating has been selected. The analysis of variance (ANOVA) has been used to determine effect of each parameter on wear rate so Finally, the confirmation test has been carried out to compare the predicted value of wear rate with the experimental value.

Starch/poly(butylene adipate-co-terephthalate) blown antimicrobial films based on ε-polylysine hydrochloride and different nanomontmorillonites

With increasing awareness on environmental protection and food safety, the development of biodegradable antimicrobial packaging materials has been paid growing emphasis. In this work, starch/poly(butylene adipate-co-terephthalate)/ε-polylysine hydrochloride films were prepared by extrusion blowing, and five commercial organically modified nanomontmorillonites (OMMT, including DK1, DK2, DK3, DK4, and DK5) were used as reinforcing agents. Intercalated structures were formed in the nanocomposite films, especially for those with DK3 and DK4 owing to their higher hydrophobicity and larger interlayer spacing. Adding OMMT weakened hydrogen bonds and the gelatinization/plasticization degree of starch. Morphology analysis revealed that the agglomeration of OMMT occurred in the films, but the film containing DK3 still showed a relatively homogeneous microstructure. Loading OMMT enhanced the strength, deformation resistance, thermal stability, surface hydrophobicity, but decreased barrier properties and water sensitivity of the films. Antimicrobial activity showed that the OMMT and ε-polylysine hydrochloride possessed a synergistic effect against Staphylococcus aureus and Escherichia coli. The maximum inhibition rate was observed in that with DK4, approaching 100 %. Findings supported the application of commercial OMMT in manufacturing biodegradable antimicrobial blown films.

Suitability of MRF Recovered Post-Consumer Polypropylene Applications in Extrusion Blow Molded Bottle Food Packaging.

Polypropylene (PP) is one of the most abundant plastics used due to its low price, moldability, temperature and chemical resistance, and outstanding mechanical properties. Consequently, waste from plastic materials is anticipated to rapidly increase with continually increasing demand. When addressing the global problem of solid waste generation, post-consumer recycled materials are encouraged for use in new consumer and industrial products. As a result, the demand is projected to grow in the next several years. In this study, material recovery facility (MRF)-recovered post-consumer PP was utilized to determine its suitability for extrusion blow molded bottle food packaging. PP was sorted and removed from mixed-polymer MRF-recovered bales, ground, trommel-washed, then washed following the Association of Plastics Recyclers' protocols. The washed PCR-PP flake was pelletized then manually blended with virgin PP resin at 25%, 50%, 75, and 100% PCR-PP concentrations and fed into the extrusion blow molding (EBM) machine. The EBM bottles were then tested for physical performance and regulatory compliance (limits of TPCH: 100 μg/g). The results showed an increased crystallization temperature but no practical difference in crystallinity as a function of PCR-PP concentrations. Barrier properties (oxygen and water vapor) remained relatively constant except for 100% MRF-recovered PCR-PP, which was higher for both gas types. Stiffness significantly improved in bottles with PCR-PP (p-value < 0.05). In addition, a wider range of N/IAS was detected in PCR-PP due to plastic additives, food additives, and degradation byproducts. Lastly, targeted phthalates did not exceed the limits of TPCH, and trace levels of BPA were detected in the MRF PCR-PP. Furthermore, the study's results provide critical information on the use of MRF recovered in food packaging applications without compromising performance integrity.

The Role of Interchain Force and/or Chain Entanglement in the Melt Strength and Ductility of PLA-Based Materials.

As an eco-friendly material, PLA was a desirable alternative to polyethylene and polypropylene films due to its biodegradability. The preferable melt strength of PLA-based materials was a key factor in ensuring its processing using extrusion blow. This paper focuses on the influence of interchain force and/or chain entanglement on the melt strength and ductility of PLA-based materials in recent years. In addition, the preparation of PLA-based materials via physical blending or reactive processing was also summarized. The blending of PLA with a flexible heteropolymer, driven by the interchain force and/or chain entanglements, were characterized as a practicable method for toughening PLA-based materials. Also, the restructuring of PLA chains, by branching based on chain entanglement, was suitable for increasing chain entanglements in PLA matrix, yielding satisfactory melt strength and ductility. This review aims to elucidate the relationship between interchain forces and/or entanglement with the melt strength and ductility of PLA-based materials. An essential and systematic understanding of the tailoring melt strength and rheological properties of PLA by interchain forces and/or entanglement was apt to improve and perfect the processing technology of the extrusion blow, and consequently improve the tensile strength and toughness of PLA films.