INTRAVIS - Boosting preform production: Automated efficiency through machine collaboration

2024-10-16 2:44 min Digitization, Preform measuring and inspection, PET injection moulding systems, THREE:24

Malte Nitz | Marketing | INTRAVIS | Aachen | Germany

INTRAVIS and Husky Technologies have announced a pioneering collaboration that integrates INTRAVIS’ preform monitoring system, PreMon, with Husky’s HyPET®6e platform. This collaboration, demonstrated at this year’s NPE trade show, introduces a groundbreaking closed-loop application for rPET preform production, setting new benchmarks in efficiency and enabling the circular economy

Next-Generation Closed-Loop Technology

At the heart of this collaboration is the closedloop application, which revolutionizes color correction in rPET preform production. The solution provides automatic color adjustment to reduce color variability in PET preforms made from recycled content. By using an MQTT interface for communication, the PreMon and the Husky HyPET®6e system work in tandem to monitor and adjust color values in real-time. This integration ensures fast feedback and immediate corrections, with masterbatch automatically added to immediately address any significant yellowing of the preforms. This rapid response capability aims for consistent quality and minimized waste, enhancing overall production efficiency without the need for operator intervention.

Fig 1: Closed loop between PreMon and HyPET® 400 HPP6e for automatic color adjustments (Photo: INTRAVIS)

Seamless Integration

Andreas Müller, CEO of INTRAVIS Inc., points out the good integration of both machines and the advantages for the customer: “The seamless integration of the PreMon with the HyPET®6e system enables direct and continuous feedback on color values. This real-time communication ensures that preforms consistently meet the desired specifications, improving the reliability and quality of the final product. The compact design of the PreMon requires a particularly small footprint in the production hall which leads to significant space savings. The ability to make instant adjustments sets this application apart from traditional methods: It offers a significant advantage in maintaining color consistency and reducing variability.”

Fig 2: Monitoring of color values, injection point, body, and sealing surface (Photo: INTRAVIS)

Driving Circular Economy with rPET bottle production

The collaboration also emphasizes eco-friendly innovation. At NPE, the production of a lightweight preform made entirely from 100% rPET was presented to be blown into a 595 ml bottle. Weighing just 5,89 grams, the preform supports the circular economy using recycled materials without compromising performance.

Andreas Müller is proud, that with this collaboration INTRAVIS is contributing to the goal of shaping a greener future for the plastic packaging industry: “Prioritizing recycled PET is fundamental as it helps reduce reliance on virgin plastics, lowers greenhouse gas emissions, and decreases the amount of plastic waste in landfills and oceans. By reusing existing materials, rPET production conserves resources and energy, contributing to a more sustainable and environmentally friendly manufacturing process. This sustainable approach aligns with global environmental goals and demonstrates the commitment of both companies to enable a circular economy, promoting a more sustainable future for the plastic packaging industry and beyond.”

Uncompromising HighSpeed Production

The HyPET® 400 HPP6e system on display at NPE 2024 was equipped with a 144-cavity, 45-pitch mold running at a cycle time of just 4,5 seconds, achieving a production speed of more than 120,000 preforms per hour. This high-speed capability, complemented by the PreMon, enhances production efficiency, and meets the increasing demands of the packaging industry. Both the HyPET®6e system and the PreMon are designed to handle this rapid pace, ensuring seamless integration and continuous, highquality output.

Detailed quality monitoring beyond color

In addition to color inspection, the PreMon provides comprehensive monitoring of several other critical quality characteristics in rPET preform production. The color inspection evaluates L*a*b* values, color intensity, color deviation, and yellowness effect to ensure consistent aesthetic quality. The monitoring system also includes long gate inspection to detect any overlength at the injection point, which can affect the finish of the final product.

_____________

''Prioritizing recycled PET is fundamental as it helps reduce reliance on virgin plastics, lowers greenhouse gas emissions, and decreases the amount of plastic waste in landfills and oceans.'' - Andreas Müller

______________

Furthermore, it inspects the preform body for contaminations such as black spots and contrasting impurities, which can compromise the structural integrity and appearance. The sealing surface undergoes two distinct inspections: one to detect short shots, ensuring that the preform mouth is properly formed, and another to identify any defects that could affect the sealing surface and usability of the final bottle.

This comprehensive combination of inspections ensures that each preform meets stringent quality standards, enhancing reliability and customer satisfaction. And whenever the PreMon finds a defect, the integrated ejector ensures that the preform is directly ejected!

Fig 3: PreMon integrated directly behind the HyPET®6e system on a small footprint (Photo: INTRAVIS)

Conclusion: Towards Sustainable Manufacturing

The collaboration between INTRAVIS and Husky marks a significant advancement in rPET preform production. By combining cutting-edge technology with a commitment to sustainability and efficiency, this collaboration sets a new standard in the industry. The innovative closed-loop application aspires to drive future developments and improve overall production processes, benefiting both manufacturers and consumers.

www.intravis.com