تويت
العنوان : تقرير زيارة مصنع جريكو -اريحا -فلسطين
المساق : عمليات انتاجية 1
السنة : 2008
العملية الانتاجية
Stretch Blow Molding
البحث
المساق : عمليات انتاجية 1
السنة : 2008
العملية الانتاجية
Stretch Blow Molding
البحث
Palestinian Beverage Group-Jericho
The Jericho factory is one of the high spirited manufacturers and exporters of high quality Automatic Mineral Water.
The factory has been established in 1998 ,the production started after five months later with an initial investment about 5 million dollars.
The factory situated in Nab'a Al Duk village, Jericho , on a land area about 9 donms and the building has three Floors each floor has an area about 1200 m² .
Computers in this factory are controlling all the processes in the production line that is contains machines and the products , thus the human being in the factory have low work to do, this factory has only 21 workers including Mechanical , Chemical , Electrical and Industrial engineers and other workers, all of these workers work in several positions but doesn't affect the production line just in monitoring the sequence of this line .
As an Industrial Engineer we interest in one of the processes in this factory which we studied in manufacturing processing "1"
that is Stretch Blow Molding.
that is Stretch Blow Molding.
History OF The Blow Molding
Blow molding of plastics represents a logical progression from the tradition of making glass bottles by blowing a bubble of molten glass into a mold.
U.S. Patent 237,168 was issued on February 1, 1881, to Celluloid Novelty Co. and Celluloid manufacturing Company, New York. This was the first patent for the processing of extruded polymer into a parison for blow molding.
The first applications for blow molding were for cellulose nitrate, and later, in the 1930s, for cellulose acetate. Blow molding remained a relatively small part of the plastics manufacturing scene until the introduction of Low Density Polyethylene (LDPE) in the 1940s. The production of LDPE squeeze bottles by Monsanto caused a rapid expansion of the industry, with containers produced to replace glass bottles for shampoos and liquid soaps.
The mass production of high density polyethylene (HDPE) and polypropylene (PP) in the 1950s led to a further increase in blow molding demand, for applications such as liquid detergents, motor oil, water and milk. The lightweight HDPE one gallon milk container revolutionized the dairy industry, as glass bottles and paperboard were quickly replaced.
The production of polyethylene terephthalate (PET) led to the viability of reheat stretch blow molding. The strain hardening properties of PET allowed the high volume production of bottles able to resist the carbonation pressure in soft drink applications. The high clarity and economics of PET stretch blow molding have made this a popular production method for bottles for water, detergents, and other products.
Blow molding of plastics represents a logical progression from the tradition of making glass bottles by blowing a bubble of molten glass into a mold.
U.S. Patent 237,168 was issued on February 1, 1881, to Celluloid Novelty Co. and Celluloid manufacturing Company, New York. This was the first patent for the processing of extruded polymer into a parison for blow molding.
The first applications for blow molding were for cellulose nitrate, and later, in the 1930s, for cellulose acetate. Blow molding remained a relatively small part of the plastics manufacturing scene until the introduction of Low Density Polyethylene (LDPE) in the 1940s. The production of LDPE squeeze bottles by Monsanto caused a rapid expansion of the industry, with containers produced to replace glass bottles for shampoos and liquid soaps.
The mass production of high density polyethylene (HDPE) and polypropylene (PP) in the 1950s led to a further increase in blow molding demand, for applications such as liquid detergents, motor oil, water and milk. The lightweight HDPE one gallon milk container revolutionized the dairy industry, as glass bottles and paperboard were quickly replaced.
The production of polyethylene terephthalate (PET) led to the viability of reheat stretch blow molding. The strain hardening properties of PET allowed the high volume production of bottles able to resist the carbonation pressure in soft drink applications. The high clarity and economics of PET stretch blow molding have made this a popular production method for bottles for water, detergents, and other products.
Extrusion blow molding
In Extrusion Blow Molding (EBM), plastic is melted and extruded into a hollow tube (a parison). This parison is then captured by closing it into a cooled metal mold. Air is then blown into the parison, inflating it into the shape of the hollow bottle, container or part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected.
EBM processes may be either continuous (constant extrusion of the parison) or intermittent. Types of EBM equipment may be categorized as follows:
In Extrusion Blow Molding (EBM), plastic is melted and extruded into a hollow tube (a parison). This parison is then captured by closing it into a cooled metal mold. Air is then blown into the parison, inflating it into the shape of the hollow bottle, container or part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected.
EBM processes may be either continuous (constant extrusion of the parison) or intermittent. Types of EBM equipment may be categorized as follows:
Continuous Extrusion Equipment
• rotary wheel blow molding systems
• shuttle machinery
• rotary wheel blow molding systems
• shuttle machinery
Intermittent Extrusion Machinery
• reciprocating screw machinery
• accumulator head machinery
• reciprocating screw machinery
• accumulator head machinery
Examples of parts made by the EBM process include dairy containers, shampoo bottles, hoses/pipes, and hollow industrial parts such as drums.
Basic polymers, such as PP, HDPE, PVC and PET are increasingly being coextruded with high barrier resins, such as EVOH or Nylon, to provide permeation resistance to water, oxygen, CO2 or other substances. In dairy applications, it is possible to extrude a black light-blocking layer in the center layer of containers, with opaque white resin used in the inner and outer layers.
Compared to injection molding, blow molding is a low pressure process, with typical blow air pressures of 25 to 150 psi. This low pressure process allows the production of economical low-force clamping stations, while parts can still be produced with surface finishes ranging from high gloss to textured. The resulting low stresses in the molded parts also help make the containers resistant to strain and environmental stress cracking.
Basic polymers, such as PP, HDPE, PVC and PET are increasingly being coextruded with high barrier resins, such as EVOH or Nylon, to provide permeation resistance to water, oxygen, CO2 or other substances. In dairy applications, it is possible to extrude a black light-blocking layer in the center layer of containers, with opaque white resin used in the inner and outer layers.
Compared to injection molding, blow molding is a low pressure process, with typical blow air pressures of 25 to 150 psi. This low pressure process allows the production of economical low-force clamping stations, while parts can still be produced with surface finishes ranging from high gloss to textured. The resulting low stresses in the molded parts also help make the containers resistant to strain and environmental stress cracking.
Injection blow molding
The process of Injection Blow Molding (IBM) is used for the production of hollow glass and plastic objects in large quantities. In the IBM process, the polymer is injection molded onto a core pin; then the core pin is rotated to a blow molding station to be inflated and cooled. This is the least-used of the three blow molding processes, and is typically used to make small medical and single serve bottles. The process is divided into three steps: injection, blowing and ejection.
The injection blow molding machine is based on an extruder barrel and screw assembly which melts the polymer. The molten polymer is fed into a manifold where it is injected through nozzles into a hollow, heated preform mold. The preform mold forms the external shape and is clamped around a mandrel (the core rod) which forms the internal shape of the preform. The preform consists of a fully formed bottle/jar neck with a thick tube of polymer attached, which will form the body.
The preform mold opens and the core rod is rotated and clamped into the hollow, chilled blow mold. The core rod opens and allows compressed air into the preform, which inflates it to the finished article shape.
After a cooling period the blow mold opens and the core rod is rotated to the ejection position. The finished article is stripped off the core rod and leak-tested prior to packing. The preform and blow mold can have many cavities, typically three to sixteen depending on the article size and the required output. There are three sets of core rods, which allow concurrent preform injection, blow molding and ejection.
Another application of injection blow molding is in the production of soft elastic gelatin capsule for pharmaceutical applications. Two strips of gelatin are pressed together in a rotary die which cuts out the desired shape of capsule while the fill liquid is injected. Afterwards, they are cooled and dried to yield a firm, strong capsule.
The process of Injection Blow Molding (IBM) is used for the production of hollow glass and plastic objects in large quantities. In the IBM process, the polymer is injection molded onto a core pin; then the core pin is rotated to a blow molding station to be inflated and cooled. This is the least-used of the three blow molding processes, and is typically used to make small medical and single serve bottles. The process is divided into three steps: injection, blowing and ejection.
The injection blow molding machine is based on an extruder barrel and screw assembly which melts the polymer. The molten polymer is fed into a manifold where it is injected through nozzles into a hollow, heated preform mold. The preform mold forms the external shape and is clamped around a mandrel (the core rod) which forms the internal shape of the preform. The preform consists of a fully formed bottle/jar neck with a thick tube of polymer attached, which will form the body.
The preform mold opens and the core rod is rotated and clamped into the hollow, chilled blow mold. The core rod opens and allows compressed air into the preform, which inflates it to the finished article shape.
After a cooling period the blow mold opens and the core rod is rotated to the ejection position. The finished article is stripped off the core rod and leak-tested prior to packing. The preform and blow mold can have many cavities, typically three to sixteen depending on the article size and the required output. There are three sets of core rods, which allow concurrent preform injection, blow molding and ejection.
Another application of injection blow molding is in the production of soft elastic gelatin capsule for pharmaceutical applications. Two strips of gelatin are pressed together in a rotary die which cuts out the desired shape of capsule while the fill liquid is injected. Afterwards, they are cooled and dried to yield a firm, strong capsule.
Stretch blow molding (SBM)
In the Stretch Blow Molding process, the plastic is first molded into a "preform" using the Injection Molded Process. These preforms are produced with the necks of the bottles, including threads (the "finish") on one end. These preforms are packaged, and fed later (after cooling) into an EBM blow molding machine. In the SBM process, the preforms are heated (typically using infrared heaters) above their glass transition temperature, then blown using high pressure air into bottles using metal blow molds. Usually the preform is stretched with a core rod as part of the process. The stretching of some polymers, such as PET (Polyethylene terephthalate) results in strain hardening of the resin, allowing the bottles to resist deforming under the pressures formed by carbonated beverages, which typically approach 60 psi.
The main applications are bottles, jars and other containers. The Injection blow molding process produces bottles of superior visual and dimensional quality compared to extrusion blow molding. The process is ideal for both narrow and wide-mouthed containers and produces them fully finished with no flash. A sign of injection blow molding is the seam where the two halves of the mold meet.
In the Stretch Blow Molding process, the plastic is first molded into a "preform" using the Injection Molded Process. These preforms are produced with the necks of the bottles, including threads (the "finish") on one end. These preforms are packaged, and fed later (after cooling) into an EBM blow molding machine. In the SBM process, the preforms are heated (typically using infrared heaters) above their glass transition temperature, then blown using high pressure air into bottles using metal blow molds. Usually the preform is stretched with a core rod as part of the process. The stretching of some polymers, such as PET (Polyethylene terephthalate) results in strain hardening of the resin, allowing the bottles to resist deforming under the pressures formed by carbonated beverages, which typically approach 60 psi.
The main applications are bottles, jars and other containers. The Injection blow molding process produces bottles of superior visual and dimensional quality compared to extrusion blow molding. The process is ideal for both narrow and wide-mouthed containers and produces them fully finished with no flash. A sign of injection blow molding is the seam where the two halves of the mold meet.
This picture shows what happens inside the blow mold.
The preform is first stretched mechanically with a stretch rod. As the rod travels down low-pressure air of 5 to 25 bar (70 to 350 psi) is introduced blowing a 'bubble'. Once the stretch rod is fully extended, high-pressure air of up to 40 bar (580 psi) blows the expanded bubble into the shape of the blow mold.
Production process
1st : Filtration of Water :
The water comes from two near spring (natural water resource) and they stored in large tank under the ground with an maximum volume of 100 thousands litters .
The first step in filtration is the filtration from impurities and dust ,and is done by three filters (two sand filter , one carbon filter ) after that the water enters main treatment room that make filtration to the water by ozone which reduce impurities to a range of 45-65 micro.
The water comes from two near spring (natural water resource) and they stored in large tank under the ground with an maximum volume of 100 thousands litters .
The first step in filtration is the filtration from impurities and dust ,and is done by three filters (two sand filter , one carbon filter ) after that the water enters main treatment room that make filtration to the water by ozone which reduce impurities to a range of 45-65 micro.
2nd step: Bottles Manufacturing:
Bottles are manufactured using the stretch blow molding as illustrated above.
Bottles are manufactured using the stretch blow molding as illustrated above.
3rd step: Washing:
In this process the major objective is to clean the bottle from any impurities and dusts that occurs due to the manufacturing of the bottle.
In this process the major objective is to clean the bottle from any impurities and dusts that occurs due to the manufacturing of the bottle.
4th step : Filling:
in this process another automatic machine fills the empty bottle with the mineral water with the suitable volume that is the bottle have, then another machine is closing the hole of this bottle ,then pasting the label of the company name on the closed bottle , the date of production is putting on this label .(in this process there is worker monitoring the process of filling and labeling of each bottle)
in this process another automatic machine fills the empty bottle with the mineral water with the suitable volume that is the bottle have, then another machine is closing the hole of this bottle ,then pasting the label of the company name on the closed bottle , the date of production is putting on this label .(in this process there is worker monitoring the process of filling and labeling of each bottle)
5th step : The Packaging:
After checking the success of the previous processes, and removing the defective bottle there is machine packages every eight bottles in the same package .
After checking the success of the previous processes, and removing the defective bottle there is machine packages every eight bottles in the same package .
6th step : The Quality:
when the products (bottles with water) are ready to store in the storage place, it stays at the end of the production line until the chemical lab gives its results about the water quality that is the present of the impurities and dusts in these bottles ,one of the most important inspection is PH inspection , if there is any defect all products are discharged ,but if the results show that is no defect the products are going to the store , then to the markets .
when the products (bottles with water) are ready to store in the storage place, it stays at the end of the production line until the chemical lab gives its results about the water quality that is the present of the impurities and dusts in these bottles ,one of the most important inspection is PH inspection , if there is any defect all products are discharged ,but if the results show that is no defect the products are going to the store , then to the markets .
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