Blow Molding Machine Research Articles

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.

Analysis of Process Failures in Plastic Product Manufacturing Using Blow Molding Machines

Analysis of Process Failures in Plastic Product Manufacturing Using Blow Molding Machines

Analysis of The Causes of Failure to Blow 600 ml Bottles on Blow Molding Machine with The Fishbone Diagram

Analysis of The Causes of Failure to Blow 600 ml Bottles on Blow Molding Machine with The Fishbone Diagram

Research on Properties of PBAT/CaCO3 Composite Films Modified with Titanate Coupling Agent.

High cost, low crystallinity, and low-melt strength limit the market application of the biodegradable material poly (butylene adipate-co-terephthalate) (PBAT), which has become a major obstacle to the promotion of PBAT products. Herein, with PBAT as resin matrix and calcium carbonate (CaCO3) as filler, PBAT/CaCO3 composite films were designed and prepared with a twin-screw extruder and single-screw extrusion blow-molding machine designed, and the effects of particle size (1250 mesh, 2000 mesh), particle content (0-36%) and titanate coupling agent (TC) surface modification of CaCO3 on the properties of PBAT/CaCO3 composite film were investigated. The results showed that the size and content of CaCO3 particles had a significant effect on the tensile properties of the composites. The addition of unmodified CaCO3 decreased the tensile properties of the composites by more than 30%. TC-modified CaCO3 improved the overall performance of PBAT/CaCO3 composite films. The thermal analysis showed that the addition of titanate coupling agent 201 (TC-2) increased the decomposition temperature of CaCO3 from 533.9 °C to 566.1 °C, thereby enhancing the thermal stability of the material. Due to the heterogeneous nucleation of CaCO3, the addition of modified CaCO3 raised the crystallization temperature of the film from 97.51 °C to 99.67 °C and increased the degree of crystallization from 7.09% to 14.83%. The tensile property test results showed that the film reached the maximum tensile strength of 20.55 MPa with the addition of TC-2 at 1%. The results of contact angle, water absorption, and water vapor transmission performance tests showed that TC-2 modified CaCO3 increased the water contact angle of the composite film from 85.7° to 94.6° and decreased the water absorption from 13% to 1%. When the additional amount of TC-2 was 1%, the water vapor transmission rate of the composites was reduced by 27.99%, and the water vapor permeability coefficient was reduced by 43.19%.

Modelling and analysis of a customized die for blow moulding machine

This paper concentrates on the modelling of a customized bottle shape using CATIA software and analyzed for the reaction of H13 Tool steel for thermal changes occurs inside the shape of the die designed which can be used in the blow moulding machine where HDPE material is used to extract the bottle from the designed die. From the results of analysis, the total temperature and heat flux at three different temperatures could be compared by applying thermal analysis in order to known the physical properties of the model designed by also applying static analysis. One such conceptual model can be printed using 3D metal printing for further research in this area of study. Overall, by equipping designers with a library of “bottle-design” features from a CAD/CAM system, the overall period is shortened and simplified, and the same geometrical data can be passed downstream for printing.

Mathematical Modeling and Time Dependent Availability Analysis of Poly - Ethylene Terephthalate Bottle Hot Drink Filling System: A Case Study

The current research aims to analyze the Time Dependent System Availability (TDSA) and identify the most sensitive component/unit of Poly Ethylene Terephthalate (PET) Bottle Hot Drink Filling System of a beverage Industry with Markovian approach. TDSA and Mean time between failures (MTBF) is computed for system concerned. The industrial system chosen includes five components namely Blow Moulding Machine, Filling Machine, Cooling Machine, Labeling Machine and Coding Machine. Transition diagram of the system has been developed and respective Chapman-Kolmogorov equations are originated. The derived equations are further simplified by an advance and receptive method acknowledged as adjustive step size control Runge-Kutta method. On basis of TDSA analysis most sensitive unit/component has been identified and maintenance priorities to other units/components have been assigned.

Minimize Defects in 5 Liters Jerry Cans by Using Statistical Quality Control and Root Cause Analysis

PT. DS2 is one of the producers of household appliances, kitchen utensils, and children's toys to bottles and jerry cans, to produce 5 liters of jerry using 2 Blow Molding machines that can produce an average jerry of 6750 / plastic jerry per day. In the production process there are defects found in 5 liter jerry products. This study aims to determine the cause of defect, what factors cause defect. Method used in this research is SQC and RCA in an effort to determine the defect in the 5 liter jerry production process. From the results of research that has been done, the highest value of disability is PL bloom defect with 1686 pcs with a cumulative percentage of 41%. Based on the analysis using the control p chart that all percentages of defective pruduct are still in the control chart and declared safe.

FMEA tool to analysis of blow molding machine damage

Machine performance in industry has a vital role in the production floor. The machine operates smoothly will support the achievement of production targets. One sector produces packaging products made based on plastic experiencing a failure production process due to the frequent stopping of the Blow Molding Machine. Fishbone diagram and Failure Mode and Effect Analysis (FMEA) is used to find information about the factors cause the Blow Molding Machine to stop. Fishbone diagram is used to determine the factors cause the failure of the Blow Molding Machine in running the production process. FMEA is used to identify the factors causing loss and determine the priority level of risk based on the RPN value. The mold damage factor has the highest RPN value. Mold failure is most significant cause of Blow Molding Machine stops operating. The mold is damaged when stored in the spare part warehouse due to crushed by a material made of metal. Mold is stored in an unsuitable location. Analysis using a fishbone diagram to determine the root of the problem handled.

Pet Şişe Şişirme Makinelerinde Fırın Optimizasyonu

In this study, we have consulted the information of Pet Bottle Machine manufacturers and end users; Located in a limited number of Pet Bottle Blowing Machines in Turkey has been conducted on ovens. After the preform moves around its axis since it enters the machine and reaches the required heat by passing through the oven sections, bottles are obtained by giving 40 bar high pressure in the blowing unit. The quality of the obtained bottles is very important. The reason for this is that the labeling, filling and palletizing machines are also included in the continuation of Pet Bottle Blowing Machines. If the bottles are of poor quality, the entire line stops. The most important way to ensure that the bottles are produced in a robust manner is the efficient heating of the preforms, the raw material of the bottle. This study provided more efficient application of heat treatments of prefoms. In the heat treatment of the preform, to optimize the oven zone; PLC, HMI, temperature controls, thermal heat meter, thermocupl and thermal camera are used. The instantaneous temperature values obtained from the thermal heat meter, thermocupl and temperature controls are processed to the PLC as a reference and necessary adjustments are made available to the user via HMI. The reference values imported to PLC were developed using ST language in Codesys based software. In this study, instant values are shown on the panel. By using these data, heat optimization of infrared lamps in Pet Bottle Blow Molding Machines despite variable weather conditions is provided. The heat taken from the oven, the preform which is the raw material of the bottle, which has been optimized by the software, is observed with the thermal camera; The results were compared with the standard oven. In the context of the data obtained, it was observed that the software positively affected the preform and caused the production of bottles of better quality and cost-effective which are not affected by the changing climate conditions.

The Design of Mold Clamping Mechanisms with Two Dead-Position Configurations

Blow-molding machines are divided into two types: (1) rotary type blow-molding machine, and (2) linear type blow-molding machine. Good kinematic characteristics of mold clamping mechanism is the goal pursued by manufacturers of blow-molding machine. Traditionally, the mold clamping mechanism has only one dead-position configuration for the mold in the closed position. When the mold is in the open position, the mold clamping mechanism does not have dead-position configuration. This study focuses on the design of mold clamping mechanisms with two dead-position configurations when the mold is in open and closed positions. Firstly, with reference to the existing patents, based on the Yan's creative design methodology, four design concepts of mold clamping mechanisms are synthesized. Then, according to the studies on kinematics of mechanisms, three mold clamping mechanisms with two dead-position configurations are also synthesized. The results of this paper will enhance the research and development (R&D) capability of the mold clamping mechanisms to improve industrial competitiveness.

Innovation is still alive in plastics

Held every three years in Orlando, the plastics trade show NPE lets attendees get up close to equipment they would otherwise encounter only on a factory floor. Machines—blaring noise and radiating heat—pop out plastic bottles and cups in booths next to the carpet-lined lanes of the Orange County Convention Center. Sleeves of plastic film multiple stories high rise from blow-molding machines. Robot arms incessantly repeat programmed routines to demonstrate their nimbleness. In contrast, the booths of the companies supplying the plastics industry with polymers and additives are equipped with machines no grander than hissing espresso makers to prepare drinks for guests. The main attractions of their outposts are racks of brochures and plastic-molded goods—car parts, bottles, and the like—screwed into the wall or displayed in Lucite cases. The show’s organizer, the Plastics Industry Association, claims NPE2018, held earlier this month, was the largest ever. Some 2,180 exhibitors were spread across

Air recovery assessment on high-pressure pneumatic systems

A computational simulation and experimental work of the fluid flow through the pneumatic circuit used in a stretch blow moulding machine is presented in this paper. The computer code is built around a zero-dimensional thermodynamic model for the air blowing and recycling containers together with a non-linear time-variant deterministic model for the pneumatic three stations single acting valve manifold, which, in turn, is linked to a quasi-one-dimensional unsteady flow model for the interconnecting pipes. The flow through the pipes accounts for viscous friction, heat transfer, cross-sectional area variation, and entropy variation. Two different solving methods are applied: the method of characteristics and the Harten-Lax-Van Leer (HLL) Riemann first-order scheme. The numerical model allows prediction of the air blowing process and, more significantly, permits determination of the recycling rate at each operating cycle. A simplified experimental set-up of the industrial process was designed, and the pressure and temperature were adequately monitored. Predictions of the blowing process for various configurations proved to be in good agreement with the measured results. In addition, a novel design of a valve manifold intended for the polyethylene terephthalate (PET) plastic bottle manufacturing industry is also presented.

Dynamic production control system for SME: implementation on plastic blow-moulding machine

Most small and medium-sized enterprises (SME) own less-resources to invest on highly computerised production control system, the productivity can be improved by conserved and effective tool of dynamic production control when dealing with fluctuation business demands of globalisation is essential. This study is based on the principle of advanced planning and scheduling (APS) which is adopted eM-plant with Excel to simulate dynamic production control system that can meet the requirement of APS for SME. The virtual plant is exercised by simulation of eM-plant as to compare with the precedent production control system for the plastic blow-moulding machine plant on their restricted delivery requirement. Obviously, the refine dynamic production system concludes the KPIs are benefited from refine system which shorten order responding time to 15 minutes, shrink the duration of arranging order schedule from one day manually to 20 minutes, and escalate the rate of delivery on time to 80% from 45% previously. [Received 28 September 2015; Revised 24 June 2016; Accepted 1 July 2016]

Measuring and modelling air mass flow rate in the injection stretch blow moulding process

The injection stretch blow moulding process involves the inflation and stretching of a hot preform into a mould to form bottles. A critical process variable and an essential input for process simulations is the rate of pressure increase within the preform during forming, which is regulated by an air flow restrictor valve. The paper describes a set of experiments for measuring the air flow rate within an industrial ISBM machine and the subsequent modelling of it with the FEA package ABAQUS. Two rigid containers were inserted into a Sidel SBO1 blow moulding machine and subjected to different supply pressures and air flow restrictor settings. The pressure and air temperature were recorded for each experiment enabling the mass flow rate of air to be determined along with an important machine characteristic known as the ‘dead volume’. The experimental setup was simulated within the commercial FEA package ABAQUS/Explicit using a combination of structural, fluid and fluid link elements that idealize the air flowing through an orifice behaving as an ideal gas under isothermal conditions. Results between experiment and simulation are compared and show a good correlation.

Design on curves of wall-thickness for Blow Molding Machine based on HMI

Properly control of blow molding machine’s wall-thickness relates to the quality of plastic products,design on curves is the key technology of blow molding machine’s wall-thickness control.Adopted cubic spline curve as a fitting prototype,used advanced HMI as a design platform,by cooperation with HMI configuration function and macro code,an interface of curves was designed,a good performance of human-computer interaction and core data’s transmission in the whole machine were realized.By using this method,the integration of the system was increased and costs was reduced dramatically.

Research of Control System of the Large-Scale Blow Molding Machine

Through the analysis of molding process of large-scale plastic hollow containers, this paper carries on the simulation and optimization of hydraulic system, which focuses on the high energy consumption problem of large-scale blow molding machine. According to the characteristics of long work period and great fluctuation of flow demand, the paper designs the oil supplying system that can match the actuators’ hydraulic energy demand, introduces the working process of each component in the system, and analyzes the key technology of hydraulic system as well. The design and research avoids the shortcomings such as more components, complex debugging, discontinuous control and unstable operation, substantially reduces the installed capacity of variable pump and driving motor, and in the meantime, solves the impact problem of actuators effectively, which can make hydraulic system high efficiency, energy saving and run steadily.

Key Technology of Hydraulic System Design of Large-Scale Blow Molding Machine

This paper carries on the simulation and optimization of hydraulic system, which focuses on the high energy consumption problem of large-scale blow molding machines. According to the characteristics of long work period and great fluctuation of flow demand, the paper designs the oil supplying system that can match the actuators’ hydraulic energy demand, introduces the working process of each component in the system, and analyzes the key technology of hydraulic system as well. The design and research avoids the shortcomings such as more components, complex debugging, discontinuous control and unstable operation, substantially reduces the installed capacity of variable pump and driving motor, and in the meantime, solves the impact problem of actuators effectively, which can make hydraulic system high efficiency, energy saving and run steadily.

Research on Control System of Large Capacity of Hollow Blow Molding Machine

This paper elaborate the structure of parison wall thickness control system; choice hardware of the control system; study on the determination of the thickness control method and control points of parison wall; research on the formation of the parison wall thickness curve; summed up the development process of extruding plastic machine heating method on the basis of the plastic molding machinery development; analysis the various of heating methods; summed up the advantages and disadvantages of various heating methods; explore their advantages and disadvantages for providing reference.

Structure and Design Research for 200L Extrusion Hollow Blow Molding Machine Head

On the basis of traditional hollow blow molding machine head, this paper researches the accumulating corner style machine head. This kind of machine head employs double layers and double spiral flow channels which solve the intensity problem of the large scale blow molding machine with single spiral flow channel on the fusion seam area. His paper researched the technological parameter and structure size based on the structural style.

Clariant invests to support North American packaging customers, cooperates with Melitek

Speciality chemicals firm Clariant is extending its colour and special effects' testing services for North American customers in the packaging sector, one of the company's key markets. A new production-scale stretch blow-moulding machine has been installed at its ColorWorks™ Design & Technology Center in West Chicago, IL, USA, to allow developers of PET plastic containers to evaluate Clariant colour and special-effect masterbatches in full-size, three-dimensional bottles instead of flat injection-moulded chips.