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PET Bottle Blow Molding Machine 101: The Ultimate Guide ...

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Blow Molding Machine 101 includes all the answers you may want to know about blow molding machine production, operation, and maintenance.

What Is A Blow Molding Machine?

Definition

A blow molding machine is designed to create hollow containers. Generally, these machines can be categorized into pneumatic blow molding machines and hydraulic blow molding machines. Pneumatic machines usually produce containers under 10L, while hydraulic machines, with their higher energy consumption, handle containers above 10L.

Broadly, blow molding machines encompass several types, including extrusion blow molding machines, injection blow molding machines, and the popular two-step blow molding machines!

The majority of blow molding machines follow a two-step process. This involves molding the plastic raw materials into preforms first, then blowing them into containers. PET polymers, which are environmentally friendly, are increasingly being used.

Purpose of a Blow Molding Machine

After the liquid plastic is extruded, it is blown into a mold cavity by wind, producing the final container. This kind of machine is known as a blow molding machine. Hydraulic blow molding machines also fall under this category.

What Is The Blow Molding Process?

The blow molding process involves placing a hot (or softened) tubular plastic parison into a split mold. Once the mold is closed, compressed air is fed into the parison, causing it to inflate and adhere to the inner walls of the mold, producing hollow objects upon cooling and demolding.

History Of The Blow Molding Process

The blow molding process dates back to World War II when it was first used to manufacture low-density polyethylene vials. By the late 1950s, blow molding became widespread with the advent of high-density polyethylene and modern blow molding equipment.

Various plastics such as polyethylene, polyvinyl chloride, polypropylene, and polyester are suitable for blow molding, with the resulting hollow containers frequently used as industrial packing containers.

What Are The Factors That Affect The Production Of Bottles By The Blow Molding Machine?

The production process is influenced by factors such as:

• Preform and its heating
• Pre-blow (position, pressure, and flow)
• Stretch rod
• High-pressure blow (pressure, position)
• Mold

Preform

PET pellets are used to make the preform, also known as the parison. The use of recycled materials should not exceed 10%, and preforms must be cooled for at least 48 hours before use after injection molding or heating.

Heating

The heating of the preform is done by a furnace, which is set manually but adjusted automatically. Proper heating avoids defects such as uneven wall thickness, enlarged bottle mouth, and a hard neck.

Pre-Blow

Pre-blowing helps the preform assume shape while also stretching it longitudinally to enhance its strength. The position, pressure, and flow of the pre-blow significantly affect the quality of the bottle.

Stretch Rods

The stretch rod extends the heated preform during pre-blowing and resets after high-pressure blowing. Proper adjustment ensures the bottle's center point is not displaced.

High-Pressure Blow

High-pressure blowing fully stretches the molten material, molding it into a bottle. The pressure (typically between 3.7 and 4 MPa) and the position of high-pressure gas are crucial elements in this step.

Molds

Molds affect bottle blow molding significantly. They must be maintained at a steady temperature and kept clean. Inconsistent mold temperature can lead to defects such as crooked bottle necks and changes in volume and height.

What Is The Production Process Of The Blow Molding Machine?

Preheating

The preform is heated by an infrared lamp, but the bottle mouth is cooled to retain its shape.

Blow Molding

The preheated preform is then placed into a blow mold where it is inflated under high pressure to form the desired bottle. Blow molding machines can be automatic or semi-automatic.

Automatic Plastic Bottle Blowing Machine accomplish both preform loading and bottle blowing automatically, accelerating production rates at a higher cost compared to semi-automatic machines.

What Is The Daily Operation Procedure Of The Blow Molding Machine?

Daily operation includes:

1. Applying lubricating oil before each shift.
2. Checking for oil leaks and ensuring all components are securely fastened.
3. Verifying air supply, power supply, and water supply are functional.
4. Testing emergency switches and protection devices.
5. Ensuring proper operation of the heating head and checking for any damages.
6. Inspections of pneumatic components for leaks and responsiveness.
7. Cleaning the blowing mold regularly.
8. Slowly opening air source switches to avoid contamination.
9. Starting the machine properly, monitoring for abnormal noises, and ensuring safety protocols.

How To Adjust The Quality Of The Bottles Produced By The Blow Molding Machine?

• If the bottle is milky white, reduce the heating temperature.
• If the bottle is blue or stretched white, increase the heating temperature.
• Adjust pre-blowing to correct belly button defects at the bottom.
• Modify the heating temperature to fix bottle mouth deformation.
• Adjust pre-blow timings for consistent bottleneck thickness.

How To Master The Troubleshooting Method Of Blow Molding Machine?

• Record various parameters such as pressure, speed, current, and voltage.
• Monitor the status of the hydraulic system's pressure gauges.
• Maintain a notebook to record daily troubleshooting events and solutions.

What Are The Bottle Blowing Machine Manufacturing Equipment On The Market?

Most blow molding machines in China are advanced two-step machines from Germany, France, and other countries, with outputs ranging from thousands to 20,000 bottles per hour.

What Are The Parts Of The Blow Molding Machine?

The machine usually consists of five main parts: blank supply system, heating system, main engine, control system, and auxiliary machinery. The control system, which is fully computer-controlled, is crucial for ensuring the machine's optimal operation.

What Is The Overall Situation Of The Blow Molding Machine Now?

With rising crude oil prices, the cost of plastic raw materials has also increased. Manufacturers aim to reduce container weight and improve energy efficiency and environmental impact, leveraging advanced technology.

Domestic manufacturers focus on developing new technologies to improve quality and gain larger market shares. One-step machines, integrating multiple processes in a single machine, save energy and production time.

Squeeze blow molding is more economical, especially for bottles with complex shapes. Market competition emphasizes speed, with some models producing up to 6,000 pieces per hour. PET material's transparency, gloss, and chemical stability make it widely used in food and daily chemicals packaging.

What Are The Advantages Of One-Step Blow Molding Machine?

The one-step blow molding machine from Japan's AOKI Research Institute uses patented technology to produce high-quality plastics directly from raw materials, saving energy and costs. Its Direct Heatcon method allows for efficient temperature regulation and uniform container production, eliminating the need for safety margins and reducing material waste.

AOKI machines, capable of molding various materials, produce lightweight and economical containers. These machines can also use recycled PET materials, saving on recrystallization costs and maintaining product quality.

AOKI introduced the "Ugly Duckling", a half-material PET container that can be compressed by hand, reducing waste volume and showcasing advantages despite its unconventional shape. This innovation meets environmental standards and market demands for lightweight, user-friendly packaging.

What Innovations Does The Blow Molding Machine Have In Terms Of Control?

The preform heating system uses infrared heating with each layer independently controlled, ensuring an ideal temperature curve. The operating system features a human-machine interface that reflects production status, with touch screen control for each mold's blowing parameters. Safety systems protect against equipment damage and ensure operational safety.

Maintaining regular updates on equipment and innovations can help achieve the best production efficiency and quality in blow molding operations.

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