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Your Key To Success: BLOW MOULDER ADJUSTMENT FOR SUSTAINABILITY

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Fully automatic bottle blow molding machine

Approximately 55% of the plastic bottles produced in the United States are used for beverage filling and plastic bottle manufacturing. Half of the industry’s revenue comes from carbonated soft drink bottles, according to a September 2013 report “Plastics Bottles are made in the United States.” It pointed out that, in fact, due to demand from the beverage industry, this $13 billion industry is expected to grow by 0.2% this year and 1.9% annually by 2028. Therefore, the plastic bottle manufacturing industry is expected to grow steadily in the next few years, it added.

01.

sustainability

SIPA North America Inc. North America Sales Director Denis Marcon said that as the plastic beverage bottle market expands, manufacturers are looking for ways to reduce total cost of ownership and environmental impact, while maintaining the flexibility needed to compete in the market. Atlanta. He explained that this could mean saving energy, producing light-weight containers to save materials, and efficient operations.

Marcon said that in order to help the company achieve these goals, SIPA is currently revamping all of its machines to reduce at least 15% of the global impact of materials and energy on plastic bottle manufacturing.

Similarly, the company recently introduced new technologies to reduce the use of materials and energy. For example, although the thickness of preforms was limited before injection molding became impossible, SIPA’s Xtreme machines allowed the production of preforms that were as much as 10% lighter than typical lightweight injection molded preforms without losing any key characteristics. The company said. To achieve this goal, SIPA uses injection compression technology, in which the mould opens slightly at the beginning of injection and then closes at the end of metering, requiring lower injection pressure and lower clamping force, it explained. By using injection compression technology, the machine can produce plastic bottles with a length-to-wall thickness ratio of 80 using preforms with the body and base removed from the extra weight, it said.

Also to help reduce energy consumption, SIPA launched the SFR EVO3 stretch blow moulder for polyethylene terephthalate (PET) bottles in July.

From an efficiency point of view, SFR EVO3 can achieve a maximum output rate of 2,250 bottles per hour in each cavity. Various models offer 6 to 16 cavity capacities, and 20 and 24 cavity models will be released later this year. In addition to this production efficiency, SFR EVO3 also improves energy efficiency through its “green” oven and mechanical compensation during the blowing process. The company stated that the use of new lamps and special materials and reflector coatings for “green” ovens can reduce power consumption by as much as 40% while maintaining stable process conditions. For the blowing process, the machine uses high-pressure blowing only at the last millimeter of the blowing, not during the entire blowing process, which helps to reduce air consumption, especially for smaller bottles, it added.

Krones, based in Franklin, Wisconsin, is also committed to using air more efficiently throughout the packaging chain, including through its Contiform blow moulder machine. “Krones has minimized the amount of excess and wasted air in the blow moulder machine by continuously designing and developing small-volume valves, small-volume compensation, and reducing operating air requirements,” explains Adam Stowitts, plastic technology product manager. In addition, the company uses Air Wizard air circulation flow, which is operated by the blow moulder control system and recovers the remaining air in the bottle, he said.

KHS USA, Waukesha, Wis. is a division of KHS GmbH that provides similar functions through the development of the Airback Plus of its InnoPET Blomax stretch blow moulder . The system allows
Approximately 40% of the compressed air used in the stretch blow molding process is reused in the blow molding wheel, the company said. In turn, machines equipped with Airback Plus require less energy, less high-pressure air, and smaller compressors, thereby helping equipment owners save investment and operating costs, it added.

02.

Big picture

In addition to achieving material and energy efficiency, the plastic bottle manufacturing industry is also striving to improve the overall efficiency of the production line. “The reality is that brand owners must bring their products to market in the most cost-effective manner possible,” Krones’ Stowitts explains. “The solution is to keep the production flow as tight as possible while maintaining sufficient output to reduce material costs. … In other words, production should be as vertically integrated as possible-compact, flexible and efficient.”

To maximize efficiency, Krones designed the Ergobloc system, which integrates a Contiform blower, filling machine and labeling machine. Stowitts explained that the system is designed to protect lightweight bottles through active control and gentle handling throughout the bottle manufacturing process. In addition, the system uses a servo joint control system to control the speed and transmission between processes to maximize uptime, he said.

03.

Strive for hygiene

According to GEA Process Engineering in Solborg, Denmark, connecting various machines during the plastic bottle manufacturing process also helps prevent pollution. GEA’s ABF system combines its aseptic blower with an aseptic filling machine and includes a microbial isolator that runs through the entire device. The company said in a statement that in this way, the aseptic preform enters the microbiological isolator before blowing and is kept in a sterile environment until the cap is aseptically closed after filling.

This microbial isolator has two main sterile components. The company said in a statement: “In the beginning, we physically separated the dirty mechanical parts from the sterile area.” “Secondly, we designed every component in the sterile area to be able to use foaming agents. It is clean and can be disinfected with vaporized hydrogen peroxide. Then, we use redundant [High Efficiency Particulate Air] (HEPA) filter stations to pressurize the environment and classify the sterile area as Class 100.”

The company said in a statement that in order to be completely clean, the preforms need to be disinfected before entering the microbiological isolator. GEA uses a controlled flow of vaporized hydrogen peroxide to sterilize the preforms in one step after the heating furnace. The company explained in a statement that this single-step cleaning helps prevent cross-contamination. It said that if the external preform is disinfected before the internal part, the contaminants from the inside of the preform will contaminate the outside of the preform and any mechanical parts in contact with the preform.

Through these steps, plastic bottle manufacturers can help ensure that they produce the safest products for the beverage market.

The beverage market is a crowded and competitive space in the food industry, but that doesn’t mean you can’t enjoy success.  We provide insights into how neuroscience sales tips on https://ibottling.com/beverage-industry/, which can help small businesses succeed by tapping into their customers’ brains and understanding them better than competitors!

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