Sustainability and overall operating costs are the major factorsheeded by beverage companies today when investing in a stretch blow molder.Design specifications for the next generation of KHS Corpoplast stretch blowmolders thus stipulated that a production process be implemented that saveseven more energy, while again cutting down on materials and optimizing lineutilization. And that everything be tailored to suit the customer's exactspecifications according to QFD* – in addition to, of course, guaranteeingabsolutely top PET bottle quality!
In place of a maximum possible output of 43,200 PET bottles per hour, theInnoPET Blomax Series IV is now able to produce up to 72,000 plastic bottlesper hour. The InnoPET Blomax series of machines is completely modular andcan be equipped with 4 to 36 blow stations. While the previous system wasable to output 1,800 PET bottles per hour and blow station, the new Series IVcan handle up to 2,200 bottles an hour.
Trumping KHS Corpoplast stretch blow molding technology, based on over 30 years of experience, was something numerous industry experts claimed to be practically impossible, as the generation before the present InnoPET Blomax Series IV stretch blow molders had already achieved best possible results. It had, for example, the lowest energy consumption per stretch blow molded container of all the stretch blow molders used in the beverage industry. Moreover, for many years InnoPET Blomax stretch blow molders have been synonymous with the high-precision production of lightweight PET bottles, optimum process stability, and a machine availability that is second to none. Ultimately, the outstanding data of the Series III was improved even further in the development of the new InnoPET Blomax Series IV generation of stretch blow molders. This is documented among other things by the use of prototypes in practice, an approach adopted for the past two years now.
In place of a maximum possible output of 43,200 PET bottles per hour, the InnoPET Blomax Series IV is now able to produce up to 72,000 plastic bottles per hour. The InnoPET Blomax series of machines is completely modular and can be equipped with 4 to 36 blow stations. While the previous system was able to output 1,800 PET bottles per hour and blow station, the new Series IV can handle up to 2,200 bottles an hour. The standard InnoPET Blomax Series IV manufactures bottle sizes ranging from 0.2 to 2.0 liters. It is also possible to produce special sizes.
Compared to the previous generation, the InnoPET Blomax Series IV halves the preheating time for preforms, made possible by the use of a new heater. The amount of space required for the heating module has also been reduced by approximately 50% in comparison to the Blomax Series III. Instead of using classic infrared radiation, the preforms are now heated using near infrared radiation or NIR. Placing the preforms in a closed heater reflector chamber aids the extremely intense heat penetration of the preform walls by NIR. Energy savings of up to 30% are possible versus traditional heating technology.
The blow stations have also been redeveloped in the InnoPET Blomax Series IV. As they are staggered on the blowing wheel and the blow stations are now only opened on one side, more blow stations than have been previously possible can be integrated onto one blowing wheel of the same size. Their modified design, that now no longer features a lock, for example, enables each individual blow station to produce more PET bottles per hour than before (2,200 instead of 1,800).
The method of preform handling is yet another innovation that distinguishes the next generation of stretch blow molders. The principle of guiding preforms with mandrels used successfully for decades has been greatly optimized. The active mandrel now used instead of a passive one not only conveys the preforms extremely gently but also holds them securely in place. The active mandrel guides the preform through the heating module, passes it on to the gripper that takes it to the blow station, picks up the next preform, and then transports it through the heating process. In the next generation of stretch blow molders, there is thus no need for a complex transfer system as was the case for mandrels that accompanied the preforms throughout the entire blow molding process. This not only saves space and parts but also increases the availability of the system and simplifies maintenance.
The preforms are stretched and blown in the InnoPET Blomax Series IV blow stations. The stretching process, however, is no longer a mechanical camcontrolled process, but is now driven by a servo motor and spindle. The advantage here is that even if the speed of the blow molder is reduced, stretching motion can still be carried out at the same speed despite the slower machine rotation. This has the direct benefit of increasing the process stability and thereby also reducing the scrap rate.
Using servo technology for stretching also cuts down on the changeover work required when changing the production line over to other types of PET bottle. The stretch die is simply re-set at the display screen. When changing formats with the same necks from 0.5 to 1.5 liters, for example, the InnoPET Blomax Series IV reduces the time required for changeover by approximately 50% compared to the previous generation of machines. This is further facilitated by features such as optimized blow stations, the reduction in the number of guide parts required, and considerably improved access to the machine.
Another point worth mentioning in conjunction with the new InnoPET Blomax Series IV is that the amount of compressed air required has also been substantially lowered. Depending on the bottle volume, compressed air consumption is now reduced by 5 to 15% versus the already good figures for Series III.
All told, the new InnoPET Blomax Series IV generation of KHS Corpoplast stretch blow molders more than satisfies the customer requirements and specifications that inspired its modification; the costs of production per finished bottle are approximately 20% lower than for Series III. Industry experts consider the new InnoPET Blomax Series IV a generation of stretch blow molders that with its comprehensive range of benefits is destined to set new standards within the industry.
*Quality Function Deployment (QFD) is a quality assurance program. The aim of this method is to design, produce, and market those products and services the customer really requires. QFD incorporates all business fields in the overall responsibility to produce quality.
| Manfred Rückstein Tel.: +49(0)231-569-1339 Fax: +49(0)231-569-1226 manfred.rueckstein@khs.com |
