![]() ![]() ![]() To that end, a review of the compressor room is required to ensure optimum compressed air efficiency is achieved. Blowing bottles with lower pressure equates to significant savings. The cost to make high-pressure air is three times greater than low pressure air. Modification objectives include improved part quality create a stable process and reduce the amount of energy required to produce bottles. Some modifications can be done immediately, while others will require more time. It’s important to understand machine limitations and what needs to be addressed. Review Machine Conditions/Capabilities for Blowing Air Doing so will contribute significantly to energy cost reduction. This will also improve the overall quality because the entire line variation will be reduced. Typically, a different, slower production line operation will reduce the number of start and stops. Frequently, blow molder output speeds are set at maximum levels which contribute to energy waste. In a typical self-manufacture production layout bottles are conveyed from the blow molder directly to the filler. With more companies headed down the path of bottle self-manufacture, optimizing line efficiency is an important factor. If possible, we also want to be able to use less heat, air pressure and electrical usage to reduce energy costs. The machine needs to make “the same” bottle all the time, in an efficient manner. One of the objectives with optimizing the process is to create a process that is repeatable and sustainable. For example, a beer bottle would require barrier, material distribution and top load testing. Answers to those questions will help identify which testing methodologies are needed. For example, what is the bottle’s intended use? Is it for water, soft drinks, or another application which may require additional performance attributes. Next we want to look at package applications specifics. Reviewing the bottles’ desired performance attributes in conjunction with the machine capabilities is a key component. In addition to energy reduction objectives, what other blow molding issues exist including conditions specific to the customers’ needs? Are bottles being made in a cost-effective manner?Īt this point, we also want to look at quality records and performance data to help drive the changes that need to be made. We also want to identify constraints that need to be considered. What are the machine’s attributes, performance capabilities, etc.? What upgrades does it already have or what can be done to it to make it more efficient? That helps us understand how the machine should be setup and determine timing for the different process steps. The first step is to review the container to understand the bottle/preform relationship-specifically how the two match up. To show how these objectives can be accomplished, we will break the process down into critical steps and discuss what analysis and action is required for each. Extensive working knowledge with a wide variety of equipment and production scenarios puts PTI in a perfect position to offer review and process guidelines to optimize operations. Plastic Technologies, Inc., (PTI) Holland, Ohio, has more than 25 years experience in helping companies set up their own blow molding operations. These efforts will also help produce containers that meet all of the required quality standards. ![]() Creating an effective and efficient process, as well as monitoring and maintaining optimal process settings, can result in significant energy cost reduction. Stretch blow molding equipment requires a significant amount of energy-both compressed air and electrical-to produce bottles. ![]()
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