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MFGT 142

Polymer Processing
Blow Molding

Professor Joe Greene


CSU, CHICO

Blow Molding
Overview

Blown-Film Extrusion
Extrusion blow molding (continuous and intermittent)
Injection blow molding (hot and cold parisons)
Molds and dies
Plant concepts (layout and capacity)
Product considerations (materials, shapes, designs)
Operation and control of the process

Blow Film Extrusion


Blow molding of plastic film is a plastic forming process that
is well suited for the manufacture of film and bags.
Process

Melting resin in extruder


Form molten resin into cylinder or tube.
Blow air inside the resin bubble.
Pull film into nip rollers through guide rolls.
Pull film through a series of rollers.
Wind-up film in take-up rolls

Blown
Film
Equipment
Equipment
Extruder and screen changer
2 to 8 diameters
L/D ratios from 20:1 to 34:1
Screws are deep cut with melt separation flights.

Die block with oscillator, tubular die


Die diameters 6 to 36 (max. range from 2 to 100)

Air cooled ring: Single and dual-cooling orifice configurations


Tower structure with collapser and primary nip
Surface treater, secondary nip, and winder(s)

Blow Film Extrusion


Process is similar to blowing up a balloon.
Tube is cooled by air from a cooling ring around die.
The frost line is the zone where the temperature of the tube
has fallen below the softening point of the plastics.
Example, HDPE frost line actually appears frosty.

Blow Film Extrusion


Size and finish of product is controlled by

extrusion speed
takeoff speed
die or orifice opening
material temperature
air pressure inside tube.

Blow-up ratio is ratio of die diameter to the bubble diameter

Blow Film Extrusion


Film producers may slit the tubing on one edge during
windup.
If tube is blown to a diameter of 2m the flat film will have a width of
over 6 m.
Slot dies are not practical.Tubular films are desired as low-cost
packaging for some foods and garments.
Only one heat seal is needed in the production of bags from blown
tubing.

Blown films are semi-oriented


Less orientation than highly oriented sheets from slot dies.
Stretching from the tubing expanding under pressure results in less
orientation. This stretching provides balanced orientation.
Products are biaxially oriented. Machine and cross directions.
Improved physical properties result.
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Troubleshooting Blow Film


Table 11-3 (ITEC-041 Book) Pg. 179

Blown Film
Auxiliaries
Output can be tubular, lay-flat, slitters, cutters
Output can allow in-line production of slit-open or lay-flat
products, gusseted products, and variety of bags including T-shirt
bags with cut-outs.

Materials
PE- LDPE, LLDPE, HMWHDPE, etc.
PA, ionomers, polyvinylidenechloride, PVOH, EVOH, EVA alone
or blended with PE

Products
Heavy duty films (0.1 to 0.2 mm) used for covers for agriculture
Packaging: wrap, can lining, garbage bags, T-shirt bags, garment
Multilayer: (3 to 11 layers) for barrier film
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Blown Film Operation and Costs


Operation
Operating Pressure of 3,000 to 6,000 psi with max of 10,000 psi
Production rates with internal cooling range from 6 to 20 lbs per inch
of lay-flat width.
Typical Production rates of 700 lbs per hour of product & 300 ft/min
Typical production plant has 5 to 10 lines in operation.
Nip treater widths range from 24 to 144 (max. of 244)
Tension controlled nip treaters with typical tension levels of 0.125 and
1.0 lb/linear inch per mil of film thickness (1 mil =0.001)

Costs

Every year 90 new blown film lines are built (60% to replace existing)
Annual output of over 4 Billion lbs of resin over 2500 existing lines.
Production Costs (typical) are $200/hour per machine
Single-layer blown film line is $330K to $660K.
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Coextrusion line is $4 million

Blown Film Costs Spreadsheet


Operation
------------------------------------------------- --------------------- --------------------- ------------ --------------------- ------------------------------------------------- --------------------- --------------------EXTRUSION TECHNICAL COST MODEL from IBIS Cost Model
EXTRUSION TECHNICAL COST MODEL from IBIS Cost Model
Roplast uses rates 800 lbs/hr or 300 ft/min of LDPE, $200/hour billing machine
------------------------------------------------- --------------------- --------------------- ------------ --------------------- ------------------------------------------------- --------------------- --------------------Updated: 3/2/99
per hour
per year
PRODUCT SPECIFICATIONS
VARIABLE COST ELEMENTS
--------------------- --------------------Part Name
Sheet
NAME
Material Cost
$12.68
$634,128
Width
100 cm
WDTH
Direct Labor Cost
$0.41
$20,658
Maximum Wall Thickness
1 mm
THKM
Utility Cost
$0.01
$503
Average Wall Thickness
1 mm
THKA
External Surface Area
100 sq cm
SAREA
FIXED COST ELEMENTS
--------------------- --------------------Projected Area
100 sq cm
PAREA
Equipment Cost
$37.82
$1,890,863
Tooling Cost
$15.60
$780,000
Number of Cavities
1
CAV
Building Cost
$0.40
$20,116
Number of Actions in Tool
1
ACT
Maintenance Cost
$16.31
$815,461
Surface Finish [3=best]
1 [1,2 or 3]
FIN
Overhead Labor Cost
$6.62
$331,060
Cost of Capital
$30.40
$1,520,144
Annual Production Volume
50 (000/yr)
NUM
=========== ===========
Length of Production Run
1 yrs
PLIFE
TOTAL OPERATION COST
$120.26
$6,012,933
MATERIAL SPECIFICATIONS
Material Type
Material Price
Scrap Credit Value
Density
Thermal Conductivity
Heat Capacity
Melt Temp
Tool Temp
Eject Temp

HDPE
$0.88
$0.00
0.94
0.24
1675
220
45
80

------------------------------------------------- --------------------- ---------------------

PROCESS RELATED FACTORS


Dedicated Investment
Operation Rejection Rate
Material Scrap Rate
Average Equipment Downtime
Direct Laborers Per Station

0 [1=Y 0=N]
0.1%
0.5%
20.0%
0.5

$/kg
$/kg
g/cm^3
W/mK
J/kgK
C
C
C

MAT
PRICE
SCPRI
DENS
TCOND
HTCAP
MTEMP
TTEMP
ETEMP

DED
REJ
SCR
DOWN
NLAB

OPTIONAL INPUTS
Production Rate
Equipment Cost per Station
Tool Cost per Set

9144 cm/minute
$330 (000)
$30 (000)

EXOGENOUS COST FACTORS


Direct Wages
Indirect Salary
Indirect:Direct Labor Ratio
Benefits on Wage and Salary
Working Days per Year
Working Hours per Day
Capital Recovery Rate
Equipment Recovery Life
Building Recovery Life
Working Capital Period
Price of Electricity
Price of Natural Gas
Price of Building Space

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$50,000
0.4
30.0%
260
24
15.0%
8
20
3
$0.051
$6.50
$600

Auxiliary Equipment Cost


Equipment Installation Cost
Investment Maintenance Cost

20.0%
50.0%
5.0%

/hr
/yr

yrs
yrs
months
/kWh
/MBTU
/sq m

INTERMEDIATE CALCULATIONS
Part Name
Material Designation
Product Weight
Raw Material Price
Material Scrap Price
Material Density

OCYCLE
OEQUIP
OTOOL
EXOG
WAGE
SALARY
ILAB
BENI
DAYS
HRS
CRR
ELIFE
BLIFE
WCP
ELEC
GAS
PBLD
AUX
INST
MNT

CALCULATED
9144.0
$330,000
$30,000

Sheet
HDPE
100
$0.88
$0.00
0.94

g
/kg
/kg
g/cm^3

Adjusted Material Scrap


Cumulative Rejection Rate
Effective Production Volume
Tool Complexity Factor
Energy Adjustment Factor
Clamping Force
Cooling Time

0.005
0.001
50050 /yr
19542
2.6
424 kN
0.9 sec

Cycle Time

9144.0 sec

Runtime for One Station


Number of Parallel Stations
Productive Tool Life
Tool Sets/Station
Equipment Investment/Station
Tooling Investment/Set
Power Consumption/Station
Building Space/Station
Equipment
Tooling
Building
Working

Annuity
Annuity
Annuity
Annuity

2546.6%
25.47
1 yrs
1
$330,000 /station
$30,000 /tool set
0.1 kW
26.3 sq m
$3,257,501
$844,818
$63,572
$1,847,042

/yr
/yr
/yr
/yr

############################# ############ ############

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Blow Molding
Blow molding is a plastic forming process that is well suited
for the manufacture of bottles or other hollow parts.
Process

Melting resin in extruder


Form molten resin into cylinder or tube (parison) into mold
Close mold and inject air.
Part is cooled.
Part is ejected.
Part is trimmed.

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Blow Molding
Blow molding is a plastic forming process that is well suited
for the manufacture of bottles or other hollow parts.
Process (Figure 12.1)

Melting resin in extruder


Form molten resin into cylinder or tube (parison) into mold
Close mold and inject air.
Part is cooled.
Part is ejected.
Part is trimmed.

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Blow Molding
Principle Inflate a soft end thermoplastic hollow preform (or parison) against a cooled
surface of a closed mold (extrusion blow molding).
OR inject a thermoplastic material into an injection mold featuring a neck ring
and core pin. Air is injected to blow the material against a cooled surface
(injection blow molding).

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Blow Molding
Materials

Good stretchability and a high MW are preferred


HMWPE is the most widely used for high volume packaging
PP used in processes that promote orientation
PVC is used for bottles in Europe (homopolymer can be crystal clear)
PET is primarily used for injection blow molding. Preforms
injected into cold mold to an amorphous state and then reheated to
100C for blowing
Nitrile, SAN, PVDC, PPO, PC, and PA

Products
Packaging, bottles for drinks, containers for cosmetics and
toiletries, automotive containers and bumpers.
Coextrusion products for chemical resistance and structural
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Extrusion Blow Molding


Extrusion Blow Molding the parison is formed from an
extrusion die that is similar to one from blown film.
Blown film is continuous. The film is made continuously.
Extrusion blow molding is discrete. Each part is molded
individually.
Cycle time reduction

Two mold shuttle system (Figure 12.2)


Parison transfer system (Figure 12.3)
Rotating mold or carousel system (Figure 12.4)
Accumulator system for intermittent extrusion blow molding (Fig.
12.5) Very large parts (up to 120 gal) that are several times the
injection volume.

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Injection Blow Molding


Injection blow molding forms a parison by injecting a
molten resin into a mold cavity and around a core pin.
The parison is formed by injection called preform and then
blown with air to form final shape. (Figure 12.6)
Traditional injection molding machine is used to create
preform.

Mold is closed with core pin in place.


Resin injected to form a cylindrical part around the core pin.
Threads, if any, are also formed at this stage.
Mold is opened, core pin removed, and parison ejected.
Parison is transferred to a blowing station either still hot or cooled.
Second mold is closed and air is injected to form part.
Mold opens and part is ejected.
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Injection Blow Molding

The injecting and blowing cycles of injection blow


molding need not be done at the same time or even at the
same location.
Parisons can be made by injection and then either stored
until the finished blow molded parts are needed or shipped
to a satellite location where they can be blown.
Parison must be reheated if not blown right away.
Example, Soda pop bottles
Parisons are made in central location on a large, multi-cavity injection
molding machine which give economies of scale and close engineering
control over injection mold step (critical step).
Parisons are moved to blow molding site, reheated, and blown into bottles.
Advantages
The blow molder doesnt need expensive injection machine and
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injection molds, but just and oven and a blowing station.

Injection Blow Molding


Injection blow molding allows formation of a parison that can
have a non-constant cross-section resulting in better wall
thickness uniformity than from extrusion blow molding.
Stretch blow molding (Figure 12.7)
Mechanical assistance stretches the part in the longitudinal
direction at the same time blowing the part causing a stretch in the
part along the hoop or radial direction.
Results in biaxial orientation and increased properties.
Process results from a telescoping mandrel or core pin that extends
to push on the bottom of the preform at the same time that the air is
being injected to push against the walls to stretch the material
radially.
Advantage is improvement in mechanical properties.
Higher burst strength and higher impact strength.
PET soda pop bottles use this technique to cause some crystallization and
improved properties to pass 6 foot drop test.

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Comparison
Extrusion and Injection Blow Molding
Extrusion blow molding is characterized by:

Best suited for bottles over 1/2 pound (200 g) and shorter runs.
Machine costs re comparable to injection blow molding.
Tooling costs are 50% to 75% less than injection blow molding.
Generates 20% to 30% scrap due to sprue and head trimming.
Requires additional equipment to grind scrap and reuse.
Total cycle time is shorter due to less parison transfer time.
Wider choice of resins possible due to resins with higher
viscosities can be used.
Final part design flexibility can be greater with the use of
asymmetrical openings.

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Comparison
Extrusion and Injection Blow Molding
Injection blow molding is characterized by:

Scrap free.
Better suited for long runs and smaller bottles.
Higher accuracy in the final part.
Uniform wall thickness.
No seam lines or pinch marks
Transparencies are best because crystallization can be better
controlled and the blowing can be more stress free.
Improved mechanical properties from improved parison design and
from stretch blowing.

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Blow Molding Molds


Molds and Dies
Made from tool steel and is similar to extruded pipe and blown film dies.

Programmed Parison Formation (Figure 12.8)


Improves part uniformity of extrusion blow molded parts.
Method employs an extrusion die that has a mandrel with a conical
shaped end.
The slope of the sides of the cone on the mandrel is not quite as steep
as the slope of the sides of the opening.
When the mandrel and outer die move relative to each other, the gap
between them will open or close, depending on the direction of
movement.
Feature is used to make prison that is thicker at the bottom than at the
top, thus compensating for the natural thickness variation in blow
molded due stretching.
Variation in thickness is accomplished by timing the movement of
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die/mandrel with the extrusion of the parison.

Blow Molding Molds


General Mold Considerations

Does not require high pressure like injection molding.


Aluminum (cast or machined) is the most common material.
Disadvantage to Al is the excessive wear.
Steel inserts can be used for wear areas, e.g., pinch-off.
Cast steel can be used for long production runs.
Epoxy molds with Al filler can be used for prototype.
Molds are two halves with cooling lines.
Proper venting is important to prevent air traps.
Surface of the mold is not polished or chromed.
Engraving of logos is common.
Blowing point is through a hole in the top or bottom of mold.
Ejection can be through gravity or mechanical assist.
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Blow Molding Molds


Sliding/Compression Blow Molds
Molding a recessed ring or lip onto blow molded part by applying
compression to certain areas of part, e.g., flower pot, undercuts, etc.
Process (Two flower pots are made)
Mold closes around parison which is blown in normal method.
The parison flows around a recess in the side of the mold (top of flower pot).
Before the parison is cool, the upper and lower sections of the mold slide toward
the center portion, which is fixed. The sliding motion compresses the material
that is in the gaps between the sliding parts of the mold and the fixed parts. The
reinforcement ring is formed.

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Plant Concepts
Blow molding equipment are self contained and do not
need extensive cooling or part removal as in extrusion.
Removal and handling of scrap.
Scrap removal station automates pinch-off removal.
Scrap is chopped and blended with virgin material.
Common practice is 2% regrind. Max is 50%. Properties drop after 20%.

On-line filling and labeling is done with automation.

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Materials

Product Considerations

HDPE (stiff bottles, toys, cases), LDPE (flexible bottles), PP


(temperature resistant bottles), PVC (clear bottles, oil resistant),
PET (soda pop), PC (housings), nylon (fluid containers), and FEP.
Polyolefins (HDPE, LDPE, PP) are easiest to process but are
sensitive to oils and can have stress cracking problems.
PVC is very temperature sensitive and rarely used because of
thermal degradation and safety concern for HCl.
Post consumer regrind can be used with virgin material.

Shapes

Hollow parts that are usually cubical or cylindrical.


Molded parts can be cut in two to yield two parts.
Wall thickness is limited to 1 cm (0.5 in) or less.
Wall thickness variation is a problem with thicker at bottom due to
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parison sag.

Product Considerations

Shapes (continued)

Corners and edges should have generous radius to reduce


stretching effect around corners.
The shape of the bottom should be concave rather than flat to
ensure a thicker bottom and provide more stability (non-rocking).
The opening at top of the bottle can have the threads molded in,
which will have variations in dimensions.
Volume of container can be adjusted with the use of inserts that
reduce to volume of cavity in the mold and can be seen as a round
indentation as in milk jugs.
Handles can be molded in part by blowing the part past a pinch
point that is opened so that further blowing can fill the handle.
Handles and inserts can be attached to the outside of part when the
insert is added to cavity before blowing.
Mold _ Diameter
Blow
_
Ratio

Important parameter is blow ratio


(1.5 to 3 common) Ability to expand

Parison _ Diameter

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Operation and Control


Important process control parameters

stretch (sag) of parison,


temperature of the parison and temperature of work space,
melt flow characteristics of resin
speed of parison formation
crystalline nature of the polymer,
cooling capacity of the mold.

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Trouble-shooting Guide for Blow Molding


Table 12.1

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Case Study 12.1


Making Soda Pop Bottles
Performance requirement (after 120 days)

less than 15% loss of CO2


no off-taste, no change of shape (swelling), no fall in liquid level,
drop test of 6 feet with no cracks or leakage, burst test for CO2
PET had excellent barrier properties versus PVC (2x), HDPE
(52x), PP (57x), and LDPE (114x).

Stretch blowing development improved properties of PET.

PET is injected at 480F-540F and then quenched. (resin is dried)


Preforms can be stored or shipped for final forming.
PET preform is heated to 200F (60F higher than that Tg)
Hot PET is stretched and blown to form crystals which are small
and do not reflect much light.
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