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Polymer Processing
Blow Molding
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
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.
extrusion speed
takeoff speed
die or orifice opening
material temperature
air pressure inside tube.
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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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
HDPE
$0.88
$0.00
0.94
0.24
1675
220
45
80
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)
12
$50,000
0.4
30.0%
260
24
15.0%
8
20
3
$0.051
$6.50
$600
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
0.005
0.001
50050 /yr
19542
2.6
424 kN
0.9 sec
Cycle Time
9144.0 sec
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
11
Blow Molding
Blow molding is a plastic forming process that is well suited
for the manufacture of bottles or other hollow parts.
Process
12
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)
13
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
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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16
19
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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24
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%.
25
Materials
Product Considerations
Shapes
Product Considerations
Shapes (continued)
Parison _ Diameter
27
28
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