Complete Hand Book Of Blow Moulding Plastics Technology With Project Profiles (Extrusion Blow Moulding, Stretch Blow Moulding, Injection Blow Moulding, Plastic Bottles Blow Moulding, Pet Blow Moulding And Rotational Blow Moulding)

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The book covers Technology of Blow Moulding, Blow Moulding Process,Internal Cooling for the Blow Molding Industry, Multiaspect Analyzes of Blow Moulding Process, Plastic Bottle Blow Moulding, PET Blow Moulding Machines,Rotational Blow Moulding Process, Moulds, Rotational Blow Moulding Machinery, Materials for Rotational Blow Moulding, Quality Control in Rotational Blow Moulding, Plant Economics of blow Moulded Plastic Containers, Plant Economics of HDPE, PVC and CPVC Pipes and Fittings, Plant Economics of Injection and Blow Moulded Plastic Products, Plant Economics of Injection Moulded Plastic Autoparts, Plant Economics of Injection Moulding of Chairs, Plant Economics of Injection Moulding Unit, Plant Economics of PET Bottles Recycling Plant , Plant Economics of PET Injection moulding used Mainly for Mineral Water Packing (PET Preform), Plant Economics of Pet Preform and pet Jars, Plant Economics of Plastic Water Storage Tanks, Plant Economics of uPVC Windows from uPVC Profiles.

TECHNOLOGY OF BLOW MOLDING

Extrusion blow moulding
Continuous extrusion equipment
Intermittent extrusion machinery
Spin trimming
Injection blow molding
Injection Stretch blow molding process
Advantages
Disadvantages

BLOW MOULDING PROCESS

Basic Blow Moulding Process
Extrusion Blow Moulding
Injection Blow Moulding
Stretch Blow Moulding
Injection Stretch Blow Moulding
Extrusion Stretch Blow Moulding
Injection blow moulding
Injection stretch blow moulding process sequence
Polymers used for Blow Moulding Process
Requirements for Blow Moulding Materials
Process Based Requirements for Material Suitability
Extrusion blow moulding
Injection blow moulding/Stretch blow moulding
Coextrusion blow moulding
End use criteria for material selection
Selection of Material for Packaging Application
End use applications of polypropylene Blow moulded products
Mineral water bottles
Properties of Repol Blow Moulding Grades
Why polypropylene for blow moulding
Processing Polypropylene
Screw and Barrel Design
Processing Temperatures
Tooling for Polypropylene
Moulds
Deflashing
Parison Transfer
Resin Properties
Additives
Shrinkage
process of Blow moulding
Basic Features of a Typical Mould
Continuous extrusion machines
Accumulator head machines
Co-extrusion and sequential 3-D blow moulding
Hard component Soft component
Laydow process
Movable mould
Movable die head
Laydown process
Parison manipulation process
3D Suction process
Injection blow moulding
The blow moulding machine important considerations
Screw and barrel design
Suction blow moulding process
Suction blow moulding process
Suction blow moulding process
Manifold/adapter design
Accumulator & continuous extrusion head design
Die/head tooling design
Divergent head tooling
Convergent head tooling
Parison cutters
Mould clamping force
Temperature control
Auxiliary equipment
Machine operating conditions
Quick reference
Barrel temperatures
Adapter, head and die temperatures
Summary of processing recommendations for blow moulding resins
Accumulator push-out pressures & speeds
Parison programming
Mould temperature
Start up procedures
Purging and shutdown
Secondary operations
Special conditions for injection blow moulding and pressblower (Ossberger) operation
Injection blow moulding conditions
Blow Moulding Conditions Ossberger SBE 50 Machine
Handling of blow moulding resins
Effects of moisture
Drying
Regrind
Bulk Storage
Mould design guidance
General
Blow up (draw) ratio
Mould shrinkage allowances and part dimensions
Pinch off designs
Other mould considerations
Double Dam Pinch off Design
Troubleshooting guide

INTERNAL COLLING FOR THE BLOW MOLDING INDUSTRY

Blow Molding Process
Mold Sweat
Internal Air Cooling Systems
The Blowing Tools and the Blow Valve blocks
The Blow Molding Booster
The blow Air Chiller

MULTIASPECT ANALYZES OF BLOW MOULDING PROCESS

Schematic division of the blow moulding process
Methodology
Determination of the Barus number
Measurements of the temperature distribution on the parison surface
Registration of the phenomena which occur during the blowing stage
Investigation results
Barus effect
Exampled of the results for Barus number for individual values of the extrusion nozzle gap G (mm
Temperature distribution on the parison surface
registration of the phenomenon which occurs during blowing process

PLASTIC BOTTOLE BLOW MOULDING

Background to the Industrial Energy
Efficiency Accelerator
Background to the plastic bottle blow moulding sector
What the sector manufactures
How the sector manufactures
Factors affecting business decisions
Customer demands
Flow diagram showing the main stages of the extrusion blow moulding process and the major energy demands
How energy is used in processing
Extrusion blow moulding
Flow diagram showing the main stages of the injection stretch blow moulding proces and the major energy demands
Factors affecting business decisions in the plastic bottle blow moulding sector
EBM Electricity consumption
A breakdown of electricity consumption for an extrusion blow moulding machine
Plastic Blow Moulding
Injection stretch blow moulding
A breakdown of electricity consumption during the blow stage of injection stretch blow moulding
Impact of bottle weight
Impact of speed of production
Equipment idling
Effect of different bottle weights on energy consumption for extrusion blow moulding processes
The relationship between extrusion rate and power consumption of extruder and heater
Power consumption (kW) of an EBM machine
Power consumption (kW) of an ISBM machine
Heat loss
Thermal image showing heat radiating from a motor
Operator practice
Energy management
Energy consumption of extrusion blow moulding machines for different bottle weights
Energy consumption of injection stretch blow moulding machines for different bottle weights
Energy consumption of extrusion blow moulding machines by rate of extrusion
Opportunities
Innovation in process control
Control of granulators (EBM)
Cost
Barriers
Production planning (ISBM)
Cost
Barriers
Innovative equipment
Induction barrel heating (EBM)
Cost
Heating the barrel using induction energy
Barriers
Barrel insulation (EMB)
Barriers
Infrared lamps (ISBM)
Barriers
Next steps
Work together
Install smart metering
Think strategically
Get support

PET BLOW MOULDING MACHINES

Detailed Description
First Preferred Embodiments of a two stage process
Side view of a prior art parison
Side view of a parison incorporating features usable with embodiments of the present method
Side view of a preform according to a further embodiment of the method
Side view of a container formed
Partial side sievational view of a blow moulded PET container formed from a preform usable with one embodiment of the method
The steps of formation of a parison usable with another embodiment of the method
Side view of a die in open position for manufacture of a preform
The die of in closed position
Top view of two stage injection, blow mould machine adapted to receive preforma and biaxially orient them into blow containers according to embodiments of the method
Side section view of a lifting lowering and rotating mechanism for handle covers for use
Side view of the die
Alternative side section view of the mechanism
First and second side section views of a preform adapted for loading into the machine
Side section, close up view of the machine of Fig 6.9 showing a preform with handle cover lowered over the handle portion thereof
Perspective view of the preform of Fig 6.13
Perspective view of a container blow
Top view of the mould
Bottom view of Fig 6.17 with both half moulds in opposed retationship
Further bottom view showing the preform in the position
Plan view of a half mould adapted for blowing preforms on the machine
Section view through the half mould
Side view of the container blown in the mould from
Side view of a preform incorporating an enlarged first nonexpanding region usable with embodiments of method
Detail side section view of the neck and top handle portion of the container
Section view through the mould
An alternative side view of preform of Fig 6.24
Side view of a container blown
Side view of yet a further alternative embodiment of a preform incorporating a lengthened or enlarged first non expanding zone and adapted for blowing on the machine
Perspective view of the preform of Fig 6.24
Side view of a container blown from the preform of Fig 6.29 on the machine of Fig 6.9
Perspective view of the container
Side section view of a container blown in the mould
Plan view of a half mould for blowing the preform
Plan view of the half mould
Detail side section view of the neck and top handle portion of the container
First perspective view of a container usable with embodiments of the method particularly adapted to resist high internal pressures
First side view of the container
Second side view of the container
second perspective view of the container
Plan view of container
Perspective view of the preform
Side view of a preform from which the container can be blown
Perspective view of a container with strap connected handle according to an embodiment of the method
Side view of a preform from which the container
Side section view of the resulting container blown from the preform of Fig 6.44
Side section view of a preform having a multiple integral connection handle according to an embodiment of the method
Side section view of an alternative embodiment of a container having a multiple integral connection handle
Side section view of a preform having a multiple integral connection handle according to a further embodiment of the method
Perspective view of the preform of Fig 6.48
Side section view of a preform having a multiple integral connection handle according to a further embodiment of the method
Perspective view of a container blow of a container blown from the preform
Top view of the container of Fig 6.50
Side view of a preform utilised as stock in a stretch blow moulding machine according to an embodiment of the method
Bottom view of the container of fig 6.50
Side view of a container produced from the stretch blow moulding machine according to a first embodiment of the method
Plan view of a stretch blow moulding machine according to a first embodiment of the method
Side view of the assembly of Fig 6.56 passing through a heating phase on machine
Side view of the preform of Fig 6.53 being loaded onto a transport mandrel having a nesting shield for transport through the machine of Fig 6.55
Side view of the assembly of Fig. 6.56 being aligned prior to entry into a die on machine of Fig 6.3
Side view of the assembly of Fig 6.56 in an initial position within a die on the machine
Perspective view of the shield of the assembly of Fig 6.56
Perspective view of a 16 cavity preform mould suitable for injection moulding preforms in a first stage of a modified two stage process
Side view of the assembly of Fig. 6.56 in a blow moulding position within the die of Fig 6.59
Perspective view of a preform produced by the mould
End view of the mould of fig 6.62 in substantially open position
Side view, partially cut away of the mould of Fig 6.62
End view of the mould of Fig 6.62 in substantially closed position
Partially cut away view of the mould of Fig 6.62
Partially cut away view of the mould of Fig 6.62 in substantially open condition
Schematic plan view of a stretch blow moulding machine of a two stage process
Detail of injector nozzles of the preform unit of Fig 6.62
An end view of the mould of Fig 6.62 showing a preform injection operation,
The injector nozzle arrangement of in a shut off condition
Perspective detail view of a preform handle orienting apparatus
Sectioned view of an oriented preform attached to a mandrel of the preheating stage transport system with the preform handle located in a heat shield.
Perspective view of an indexing table for transferring oriented preforms to the mandrels of preheating stage transport system
Enlarged sectioned side view of the preform and heat shield arrangement
Preferred arrangement of a bank of heater elements arranged for preheating a preform according to the present method
Orientation
Description
Detailed Description of Methods of Manufacture Incorporating Modified Two stage stretch blow moulding Machines
Container Resistant to Internal Pressures
Tag Connected Handle
Second Preferred Embodiments of Modified two stage process
First Preferred Embodiment of a Second Stage of a Two Stage Process
Handle Orientation
Transfer to Transport System and heating Stage
Heating Stage
Rotation Through Heat Conditioning
Blow Moulding

ROTATIONAL BLOW MOULDING PROCESS

The four main stages of the rotational moulding process
The Rotational Moulding Process
Clamping of mould
Top of mould is attached and clamped
Operator begins charging mould
Securing clamp
Arm with mould & Rotolog moving into oven
Powder pouring into mould
Overview of Rotational Blow Moulding
Arm begins to rotate as oven doors close
Mould in demoulding bay being rotated into a convenient orientation to assist demoulding
Lid removal using a crane
Tank mould in cooler
Removal of mould in insert holder
Final part removal from mould
Moulding ready for finishing operations
PVC protector for sports helmet
Polyurethane rotomoulded head
Special Nature of Rotational Blow Moulding
Stages during oven heating
Advantages of Rotational Blow moulding
Rotomoulded parts with & without bubbles
Decorative lamp shades
Disadvantages of Rotational Blow Moulding

MOULDS

Sheet metal mould for a vertical tank
Mould Materials
Sheet steel
Properties of common mould mateials
Cast aluminium mould
Aluminium
Electroformed Nickel
Electroplated nickel mould of mannequin head
Comparison Between Mould Materials
Mould Design
mould Frame
Moulded-in Inserts
Multiple moulds on frame
Moulded in Handles
Temporary inserts
Typical brass inserts
Moulded in handle
Movable Cores
Threads
Large mould with movable core to aid demoulding
Movable core detail
Mould Venting
Thread detail improved through mold in Graphic Systems@Surface Enhancer
Mould Surface Finish
Highly polished mould
Movable mould showing central vent
Mould Release
Mould Preparation for Release Agent
Reactive Systems
Disiloxanes
Conventional Systems
Permanent Systems
Black teflon coated mould
Hybrid Systems

ROTATIONAL BLOW MOULDING MACHINERY

Types of Rotational Blow Moulding Machines
Carousel Machines
Fixed arm turret machine
Independent arm carousel machine
Two station shuttle machine
Two station shuttle machine with cooler bay doors
Shuttle Machines
Clamshell Machines
Clamshell machine open
Clamshell machines in series
Clamshell mechine closed
Rock and Roll Machines
Other Types of Machines
Open flame rock and roll machine
Rocking oven machine
Rocking oven machines in series
Mould opened on direct electrical heating machine
Direct electrical heating machine
Slip rings
Leonardo automatic rotomoulding machine
Mould Swing
A typical drop arm
Typical straight arm
Mould swing diameters
Mould Speed
Speed Ratio
Recommended speed ratios for various mould shapes
Oven Air Flow Amplification
Example of a Venturi (air mover)
Cooling
The Venturi principle
Developments in Machine Control
Internal Air Temperature Measurement in Rotational Moulding
Typical temperature traces for a rotational moulding cycle
Bubble formation and removal in rotational moulding
The Rotolog process control system
Monitoring Pressure Inside a Mould
Pressure and temperature monitoring system on a rock and roll or rocking oven machine
Pressure and temperature monitoring system using gas line on moulding machine
Measurement of temperature and pressure in Rotating Mould

MATERIALS FOR ROTATIONAL BLOW MOULDING

Typical Characteristics of Rotationally Moulded Plastics
Material Used in Rotational Moulding
Polyethylene
Typical usage of plastics in North American rotational moulding industry
Rotomouldability of plastics
Property changes with increasing melt index
Density ranges of polyethylene
Low Density Polyethylene (LDPE)
High Density Polyethylene (HDPE)
Typical chain branching in LDPE
Low levels of chain branching typical of HDPE and MDPE
Branching typical of LLDPE
Medium Density Polyethylene (MDPE)
Linear Low Density Polyethylene
Property changes with increasing polyethylene density
Metallocene Polyethylene
Ethylene Vinyl Acetate (EVA)
Ethylene Butyl Acrylate (EBA)
Polypropylene (PP)
Polyamides (Nylone)
EVA traffic bollard
Nylon 6
Nylon 11 and Nylon 12
Reaction Injection Moulding (RIM) Nylon
Amorphous Materials
Polyvinyl Chloride (PVC)
Fluoropolymers
Nylon roto lined pipe
Other Plastics
Additives Used in Rotational Moulding Materials
PVC exercise/fitness device
Rotomoulded polycarbonate part
Fillers
Plasticisers
Calcium carbonate filler
Lubricants
Stabilisers
Anti Oxidants
Ultraviolet Stabilisers
Flame Retardants
Crosslinking Agents
Foaming Agents
Polyurethane foam filled trolley
Drop box on mould
Pigments
Drop box on mould, open showing valve position
Foam PE door panel
Powders for Rotational Moulding-Grinding or Pulverising
Powder pigments
Stages in the grinding of powders for rotational moulding
Hopper containing granules
Granule feed system
Typical grinding mill for polyethylene
Vertical mill grinding head
Typical vertical mill grinding plates for plastic powders
Typical horizontal grinding plates for rotational moulding powders
Horizontal grinding head
Side view of cutting plates with different numbers of teeth
Grinding plate
Particle Size Distribution
ASTM E-11 US sieve sizes
Typical sieve shaker used for rotational moulding powders
Typical particle size distributions for polyethylene used in rotational moulding
Dry Flow
Equipment required for dry flow and bulk density analysis
Bulk density
Factors Affecting Powder Quality
Dry flow and bulk density apparatus
Variation of dry flow rate with bulk density for rotomoulding powders
Gap Size
Number of Mill Teeth
Grinding Temperature
Effect of grinding temperature on bulk density and dry flow rate
Effect of grinding temperature on particle shape
Micropelletising
Colouring of Plastics for Rotational Moulding
Types of Pigments
Typical tumble/dry blender
Typical high speed blender
Blender barrel
Blender blades
Compounding line
Types of pigment

QUALITY CONTROL IN ROTATIONAL BLOW MOULDING

Wall Thickness Distribution
Cross section showing greater thickness in corner of rotomoulded part
Typical wall thickness ranges for rotationally moulded plastics
Tank with shielding on lid
Shrinkage
Dial gauge and microscope attachment for determining shrinkage
Shrinkage Guidelines
Linear shrinkage values for rotationally moulded polymers
Control of Shrinkage
Effect of Release Point on Shrinkage
Effect of release temperature on shrinkage of rotationally moulded polyethylene with different typies of pigment
Other Factors Affecting Shrinkage
Release Temperature
Natural PE
Warpage
Typical warpage values for rotationally moulded plastics
Control of Warpage
Warpage as a function of cooling method and mould material
Warpage
Distance along moulding
Effect of internal cooling on the structure of a rotationally moulded plastic part

PLANT ECONOMICS OF BLOW MOULDED PLASTIC CONTAINERS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF HDPE, PVC and CPVC PIPES AND FITTINGS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF INJECTION AND BLOW MOULDED PLASTIC PRODUCTS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF INJECTION MOULDED PLASTIC AUTOPARTS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF INJECTION MOULDING OF CHAIRS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF INJECTION MOULDING UNIT

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF PET BOTTLES RECYCLING PLANT

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF PET INJECTION MOULDING USED MAINLY FOR MINERAL WATER PACKING (PET PREFORM)

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF PET PREFORM AND PET JARS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF PLASTIC WATER STORAGE TANKS

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

PLANT ECONOMICS OF UPVC WINDOWS FROM UPVC PROFILES

Plant and Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

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