ASB

SEMINAR ON RECENT DEVELOPMENT

“PLASTICS RIGID PACKAGING”

INJECTION STRETCH BLOW MOLDING

TECHNOLOGY, APPLICATION &
RECENT DEVELOPMENTS

INDIAN PLASTICS INSTITUTE, MUMBAI

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RIGID PACKAGING: PROCESS OPTIONS

ƒ Injection Molding

ƒ Extrusions Blow

ƒ Injection Blow

ƒ Rota Molding

ƒ Injection Stretch Blow Molding

ƒ Thermo Forming
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CONTAINER DESIGN CONSIDERATIONS

o A container design, while reflecting the image that the

product manufacturer or distributor wishes to project,
should meet the needs of the product, satisfy the
requirements of the market place and take into account
any constraints of the container manufacturing or filling
process.
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o When a new container is to be designed, the following
factors must be taken into consideration:-
- Barrier
- Creep
- Strain Hardening
- Top Load (Resistance)
- Vacuum Collapse (Resistance)
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CONTAINER DESIGN CONSIDERATIONS

ƒ Capacity (over flow/fill point/fill height)

ƒ Dimensional constraints (filling/transit/retailing)

ƒ Shape constraints (pressurized/non-pressurized)

ƒ Base style (basecup, champagne, petaloid style, flat)

ƒ Shaping to enhance rigidity (vacuum/capping forces)

ƒ Neck finish (dimensions / manufacturer’s identification)

to be contd… …..
Closure Type:

ƒ Retention system/seal features

ƒ Tamper evident/child resistant/dispensing

ƒ Label/decoration requirements/recycling mark on base

ƒ Label size/position (location indent in base)

ƒ Label protection features/manufacturer’s logo on base

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PROCESS SELECTION

ƒ Type of Plastics

ƒ Size of Container

ƒ Quantity Requirement

ƒ Container Design

ƒ Target Price of Container

ƒ Availability of Process Equipment & Tooling

ƒ First come First used

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INJECTION STRETCH BLOW MOLDING

o Introduced in early 1970 for production of PET Container. Now

being increasingly used also for PP/PC/ABS/PS and PEN.

ƒ Injection Molded Neck

ƒ Accurate & Complex design possible
ƒ Better visual quality
ƒ Light weight
ƒ Strength
ƒ No Trimming
ƒ No Weldline
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INJECTION STRETCH BLOW MOLDING

ƒ Higher cost of Machine & Mold

ƒ Higher Infrastructural Cost

ƒ Auxiliary Equipment & Manpower

ƒ Some Complex Design like Handle not possible

ƒ Choice of material: Limited

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LEADER IN ISBM TECHNOLOGY

ƒ Established in 1978 with paid in capital of JP¥ 3 Billion (Rs. 120 Crores).

ƒ In 25 years Co. has reached a turnover of JP¥ 20 Billion (Rs.800Crores).

ƒ Installations in more than 90 countries.

ƒ 6 fully obtained subsidiaries located in USA, UK, Germany, Mexico,

Brazil and China.

ƒ 3 wholly owned manufacturing subsidiaries in Japan, China and India.

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EXPERIENCE IN ISBM PROCESS

ƒ 4500 Machines and 6000 molds installed worldwide.

ƒ Jars and Bottles in different plastics like PET, PC, PP, SAN,

PS etc.

ƒ Special Technology for “HOT FILL” PET bottles, Multilayer

& Returnable 5 Gallon Container in PET & PC.

ƒ Containers from neck size of 19mm to 120mm.

to be contd……….
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ƒ Volume of 30ML to 20,000ML.

ƒ Single cavity to 32 cavity molding system by single and two

stage machines for almost each and every application.

ƒ Large No. of patents in the area of Plastics, Machine design,

Hydraulic, Pneumatic, Control Engineering and Material Science.

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IN INDIA

ƒ ASB International Pvt. Ltd., is a 100% Export

oriented Unit established as a fully owned subsidiary

of Nissei ASB Machine Co. Ltd., Japan.

ƒ The EOU is fully operational in India since last 5

years producing selected range of machine and molds

for worldwide customers.

to be contd……….
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ƒ The facility is set up in Ambernath, Thane with 100

crores investment in most updated state of art

manufacturing facility.

ƒ Employing over 500 trained Engineers, Managers and

Workmen to produce world class equipment. Present

Sales Volume Rs US $ 35 Million.

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“ISBM CONTAINER”
Production Methods:

ISBM Containers are traditionally made by two different methods:

1) Injection Stretch Blow Molding (Hot Preform Method):

All Processing from raw material to finished container completed

within one machine.

2) Two Stage Production Method (Cold Preform Method):

Preform production and container production are independent with

an intermediate storage phase.
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1-Stage/ 2-Stage Summary
Pure 1-stage is generally favored for;

ƒ Lower volume production requirements

ƒ Growing annual product output requirements
ƒ High variety of shapes & neck designs (brand designs)
ƒ High quality products (cosmetics, personal care, etc.)

Pure 2-stage is generally favored for;

ƒ High volume – single product

ƒ Generic container and neck designs
ƒ Lower value products
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“TWO STEP PROCESS”

Storage
&
Handling

Machine - 1 Machine - 2

Injection Molding Stretch Blow Molding

of preform into bottles
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SINGLE STAGE
ASB SERIES
• Hot Preform, Single Stage Production

ƒ Four Stations: Injection, Thermal Conditioning,

Stretch Blow & Eject

ƒ Almost 40 Models of Machines from 120 Grams shot

to 1000 Grams in Multi cavity Molding (1 to 24 Cavity)

to be contd……….
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ƒ Narrow Neck, Wide Mouth, Flat/Oval & Large

PET/PP/PC Containers. Flexible Cavitation

ƒ Still Industry Leader

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HOW PET BOTTLES ARE MADE ON ASB MACHINES BY
ISBM TECHNOLOGY

Six essential steps to stretch blow molding a PET Bottle:

1. Drying the PET: PET absorbs moisture from the

atmosphere. This must be removed before processing using
a dehumidifying dryer.

2. Plasticizing the PET: Dried PET Pellets are compressed

and melted by a rotating injection.

To be contd……...
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3. Injection molding preform: Molten PET is injected into an
injection cavity and cooled rapidly to form a “preform”.
(The original test-tube-like form from which bottles are
blown is known as a preform).

4. Optimizing the preform temperature: The temperature

of the preform is adjusted to the correct profile for
blowing.

To be contd……...
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5. Stretch Blow molding the container: The hot preform is
simultaneously stretched and blown (thereby orienting the
crystals of and strengthening the PET) into a shaped blow
mold to form a tough, light weight container.

6. Container ejection: The finished container is ejected.

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AUXILIARY EQUIPMENTS

ƒ The ISBM Process for PET requires support of following

ancillary equipments for operation of ASB Machines for stable,
efficient and trouble free running of ASB Machines and
production of consistent quality bottles/jars.

ƒ PET Resin Dehumidifying Dryer with Hopper and Auto Loader: -

This equipment is required to dry and dehumidifying PET Resin
(Residual water should be less the 50PPM) to enable production
of quality PET Containers at Dryer Temperature of 150 ~ 170°C
with 4 hrs drying time and dew point less than -40°C.

to be contd………..
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ƒ Mold Chiller: - This equipment enables rapid cooling of

preform after hot/molten resin is injected into molds, for
production of crystallized and clear PET preforms. Typical
Chiller Water Temperature: 10 ~ 15°C with Flow Rate: 120 ~
140 LPM.

ƒ Mold Temperature Controller (Optional): - Certain Molds

requires warm water/oil to be supplied to the condition stage
for preform temperature optimization.

to be contd………..
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ƒ Air Compressor: - Low Pressure air at maximum 9.9

kg/cm² is required for certain pneumatic operation on the
machine and High Pressure Blow Air typically between 25 ~
30 kg/cm² is required for blowing PET Containers

ƒ Cooling Tower: - Cooling Tower is required for Cooling the

main Heat Exchange of Machine and other parts in
machine and ancillary.
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PF/PB SERIES: (1.5 Step Single Stage)

ƒ New Concept

ƒ 300ML Size to 10,000ML upto 7,200 BPH

(500ML)

ƒ Bottle: CSD, Water, Oil, Liquor etc.

ƒ Single Stage (1.5 step): Cool Preform System

to be contd………..
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PROCESS

ƒ Preform Injection & Primary Cooling

ƒ Secondary Cooling
ƒ Preform Temperature Stabilization
ƒ Reheat
ƒ Preform Temperature Stabilization
ƒ Stretch Blow
ƒ Eject

to be contd………..
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ƒ Computer Controlled Fully Automatic Operation

ƒ 10 Model from 3 Cavity Injection/1 Cavity Blow to

32 Cavity Injection/8 Cavity Blow

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PET BOTTLE DESIGN
KEY FACTORS IN PRODUCING A
QUALITY BOTTLE:

1. Retain consistent IV by:

• Drying the resin properly

2. Produce clear preforms by:

• Thoroughly melting the PET

• Cooling fast

• Minimizing regrind (max. 5%)

to be contd……..
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3. Keep acetaldehyde low by:
• Minimizing temperatures
• Minimizing time in the melt

4. Use good preform (and bottle) design

5. Use correct IV material

6. Blow bottle at the correct temperature

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Which Method is Best?

Each method has its own merits and de-merits

The choice of method depends on:

ƒ What design of container will be produced

ƒ End use of the container

ƒ Quantity required per year

ƒ Localized economic conditions

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APPLICATION OF SINGLE STAGE
TECHNOLOGY
ƒ Pharmaceutical Bottles
ƒ Hair Oil Bottles
ƒ Personal Hygiene (Mouthwash, Shampoo)
ƒ Liquor Bottles
ƒ Agrochemicals
ƒ Wide Mouth – PET & PP
ƒ 20 Ltrs Bottles for Water in PET & PC
ƒ Baby Feeding Bottles – PC & PP
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PET
Advantages

ƒ Easy to Process
ƒ Clarity
ƒ Crystallizable
ƒ Strain Hardening
ƒ Easy to Recycle

Disadvantages

ƒ Heat Resistance
ƒ Acetaldehyde
ƒ Crystallizable
ƒ Strain Handling
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POLYPROPYLENE
Advantages

ƒ Price
ƒ Moisture Barrier
ƒ Wide Necks Easy
ƒ Temperature Resistance

Disadvantages

ƒ Clarity
ƒ Oxygen Barrier
ƒ Narrow Necks Difficult
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POLYCARBONATE
Advantages

ƒ High Temperature Resistance

ƒ Impact Strength
ƒ Good Detail
ƒ Clarity

Disadvantages

ƒ Very Expensive
ƒ Chemical Resistance
ƒ Difficult Processing
ƒ Poor Barrier Properties
ƒ Choice of Supplier
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PEN
Advantages

ƒ Temperature Resistance
ƒ Gas Barrier
ƒ Tensile Strength
ƒ Compatibility
ƒ Hydrolysis

Disadvantages

ƒ Price
ƒ Availability
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“PROPERTIES COMPARISION (POLYMERS)”

Resin Contact Oxygen Moisture

Clarity Barrier Vapour
Transmission
Clarified Clear Fair Excellent
PP(RCPP)
Poly Carbonate Clear Poor Poor

PET Clear Good Fair

HDPE Poor Fair Excellent

Poly Styrene Clear Poor Poor

PVC Clear Good Fair

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HOTFILL: PET BOTTLES
HIGH TEMPERATURE
HEAT-RESISTANT PET BOTTLES
UPTO 5400 BPH, 500ML BOTTLE

We supply:

ƒ Preform Molding Machines

ƒ Vertical High Speed Clamping Mechanism ideal for High Quality
Preforms
ƒ Preform Neck Crystallizer
ƒ It has simple cyclical Conveying Mechanism for Stable Neck
Crystallization
ƒ High Temperature Heat Resistant Bottle Blow Molding Machines
ƒ Four Step Process

to be contd………..
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ADVANTAGES

ƒ High Density: Higher Crystalinity

ƒ Highly Efficient Heat Setting Method with
Efficient Cycle Time
ƒ High Performance Bottle Reduces Filling and
Storage Costs
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DLC – PET BOTTLES

OUR LATEST DEVELOPMENT

¾ ASB Will soon announce production of High Barrier

Carbon Coated PET Bottles by use of Diamond Like
Carbon (DLC) technology. ASB is collaborating with
major Japanese Companies like Mitsubishi Shoji Plastics
Corporation, Kirin, Samco to provide complete production
line from 1500 BPH to 6000 BPH.

to be contd………..
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SOME MAJOR DETAILS:

Energy Source : Radio Frequency

Material : Hydrocarbon
Layer Thickness : 0.02 – 0.04 MM
Vacuum : 1 – 10 pa
Oxygen Permeability : 0.002 CC/Bottle/Day500ml Bottle,
30 Gms (Normal PET Bottle 0.03 –
0.05 CC/Bottle/Day
Recycling : No Problem
DLC Bottles : Beer, Wine, Isotonic Drinks, Tomato
Products
FDA approval and Patent Work in process.
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PET BOTTLES FOR
WATER COOLER
• ASB has introduced Single Stage Machines to produce
large capacity PET Bottles of upto 20,000ML using Single
& Two Cavity Molding systems.
• The large Refillable Bottles used in Water Coolers have
been Extrusion Blow Moulded Polycarbonate for many
years.
• The lowest cost PET Containers with sparkling clarity are
now a viable and cost effective alternative to
Polycarbonate.

to be contd………..
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• Containers with lifting handle inserted to the bottom of

the PET bottle is getting popular.

• Test indicate than a bottle blown into a cold mould can

shrink by 6% after 20 washes when subjected to repeated
washing in 1% caustic solution at temperature of 65ºC for
a period of 5 minutes each.

to be contd………..
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• The modern bottle washing equipment using the latest

cleaning agents can provide a satisfactory wash at
temperature as low as 40ºC. This increasing the viability
of PET Bottles for Refillable applications.

• The containers have precision molded necks which require

no additional finishing process.

to be contd………..
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• There is no “weld-line” in the base to be a potential

leakage point.

• The lack of trimming operation means there is no scrap to

be recycled.
The Biaxial Orientation achieved by the Stretch Blow
process allows lighter bottles with sparkling clarity.
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SINGLE STAGE MACHINE MODEL
ASB 650EXHD/650EXHS:
4-STATION PROCESS
MACHINE ASB ASB
MODEL 650-EXHD 650-EXHS

1. Injection Unit 2 Nos 1 No.

2. (a) Mold for 20L 2 Cavity 1 Cavity

(b) Production for 20L 100BPH 60BPH

3. (a) Mold for 10L 4 Cavity 2 Cavity

(b) Production for 10L 200BPH 120BPH

4. Maximum Wt. Of Bottle 800 Gms 800 Gms

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THANK YOU