the ibm book

INJECTION BLOW MOLDING - PAGE 1 2011 ISSUE 4

By Mike Wortley - Managing Director for Jomar Europe.CONTENTS:

1) INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 3

2) PROCESS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 3

3) BASIC PRINCIPALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 4

4) HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 5

5) COMMERCIAL PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 5

6) ROTARY TABLE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 7

7) DESIGNING FOR INJECTION BLOW . . . . . . . . . . . . . . . . . . . PAGE 9

8) MACHINE AND PROCESS CAPABILITIES . . . . . . . . . . . . . . PAGE 11

9) INJECTION BLOW v EXTRUSION BLOW . . . . . . . . . . . . . . PAGE 15

10) TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 16

11) PLACING ORDERS - DEVELOPMENT PROGRAM . . . . . . . . . PAGE 18

12) WHY INJECTION BLOW MOULDS ARE EXPENSIVE? . . . . . PAGE 20

13) PREFORM MOULD HEATING FOR IBM . . . . . . . . . . . . . . . . PAGE 22

14) WATER v OIL FOR PREFORM MOULD HEATING . . . . . . . . . PAGE 24

15) WATER - JOMAR RECOMMENDATION . . . . . . . . . . . . . . . . PAGE 26

16) MACHINE OPTIONS & THE “BOSS” . . . . . . . . . . . . . . . . . . PAGE 27

17) MATERIALS PROCESSED ON IBM . . . . . . . . . . . . . . . . . . . . PAGE 29

18) TYPICAL PRODUCTS FOR IBM . . . . . . . . . . . . . . . . . . . . . . PAGE 30

19) CLEAN PRODUCTION ON JOMAR . . . . . . . . . . . . . . . . . . . . PAGE 31

20) THE VERTICAL PLASTIFIER . . . . . . . . . . . . . . . . . . . . . . . . PAGE 36

21) SHIPPING AND INSTALLING A JOMAR . . . . . . . . . . . . . . . PAGE 41

22) ANCILLARIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 42

23) SAFETY AND OPERATING REQUIREMENTS . . . . . . . . . . . . PAGE 43

24) PREVENTATIVE MAINTENANCE FOR ALL PROCESSES . . . . PAGE 45


Jomar Corporation, with over 42 years experience of advisingnew customers on Injection Blow Moulding have produced thisbook as an introduction to the Injection Blow process

This book gives an in depth insight into the process differences,the Jomar manufacturing capabilities and general advice that will make a success of your project.

Whilst we can produce the machine and tooling to the highestspecification there are areas where you can optimize yourmanufacturing installation to simplify the production processand ultimately maximise your profits.

We, at Jomar, pride ourselves on forming very close personaland working relationships with our many customers and dobecome an integral part of your manufacturing team.

If in doubt, always ask our Sales and Service team first.

We are always available to answer your questions.

Bill Petrino - President

For up to date information on Jomar products visit

www.jomarcorp.com

It’s new, it’s informative, it’s your invitation to

examine Jomar’s information library on our range of

bottle making processes.


Figure 1 Typical injection blow moulded containers.

Extrusion blow molding-Web or scar of material from clamping

of parison prior to blowing.

Figure 2

Injection blow molding -Injection mark from preform mold,or annular rings where feed point

has spread out after blowing.

Figure 3

The Injection blow-moulding (IBM) process is used to produce millions of containers and technical

mouldings around the world, usually between 1ml to 2 litres in a wide variety of plastics for

applications ranging from pharmaceutical, personal care, household, food and automotive / chemical

uses. A typical range of bottles is shown in Figure 1.

Mouldings made by extrusion blow-moulding (EBM) will show a

scar across the base split line generated from the parison weld

(Figure 2).

Bottles made by the initial INJECTION MOULDING of a preform

can be identified by the injection point or circular scar on the

bottom of the container around the central axis

(Figure 3).

Today, with many bottles produced in PET and PP by Injection

Stretch Blow-moulding (ISBM), identification becomes more

difficult, but reference to Figure 1 may help with the

identification of typical products produced on IBM.


Nozzle

Core rod

Preform

NeckMouldInsert

Preform/Parison MouldHot

Waterlines

STAGE 1

Core rod

Preform

NeckMouldInsert

Blow Mould

Coldwaterlines

8-10°C

STAGE 2Base insert

TYPICAL

50°C

115°C

95°C

95°C

95°C

50°C

Figure 4

The first stage of the IBM process is the INJECTION moulding of the preform.

In stage 1 molten plastic is intruded or injected around the core rod (Figure 4).

The core rod produces the internal finish of the neck of the bottle, while the neck mould produces

the external thread form. This area of the mould is cooled to set up the neck finish. The test tube,

or body part of the preform, is kept hot and conditioned, so that it will develop a skin, and can then

be removed from the cavity without damage.

it is then transferred on the core rod, which also acts as the blowing mandrel, to the BLOW mould -

stage 2. Here, air is introduced through the core rod, and the preform inflates to the shape of the

blow-mould where it is cooled for ejection.

Injection blow-moulding has several advantages over extrusion blow-moulding:

• Scrap-free production of containers with injection moulded necks and seamless bases.

• Superior surface quality with no score lines.

• Uniform and designed wall thickness No undesirable thick areas or thin patches.

• Low weight and volume tolerance range.

• Good stability as there are no seam lines or pinch marks on the container base.

• High accuracy and consistency of containers, i.e. mouth, body and length dimensions.

• Mouldings have slightly improved mechanical properties due to the biaxial

stretching.

• Optimum transparency with amorphous plastics.

Ultra thin bottles, offset necks or handles cannot be produced by injection blow-

moulding.

Materials are similar to EBM, but sometimes require the addition of an internal

lubricant to reduce sticking to the mould steel at processing temperatures.


STATION 1STATION 2

STATION 3

BLOW MOLD PARISON MOLDor PREFORM MOLD

EJECTION & CORE ROD CONDITIONING

Figure 5

The original patents for IBM. go back over 50 years to W. H. Kopitke who developed the process in

a standard injection moulding machine. Other similar systems using specialised moulds were

developed in the late 1950's by Farkus, Moslo and Piotrowsky. A commercial vertical rotary turret

system similar to the Piotrowsky process was developed by Procrea SRL in Italy in the mid 1970's.

The rotary table process (Figure 5) was developed in the early 1960's by Gussoni in Italy and by

Wheaton in the USA. Today, development on this horizontal indexing system is continued by

companies such as Jomar Corporation and Uniloy Milacron in the USA.

The purpose built, fully integrated, Injection blow-moulding machines are generally divided

into two concepts as defined by the plane of rotation for the core rods mounted to the

machine table or turret; the vertically rotating turret of Procrea and the horizontally

rotating table of Jomar, Uniloy & Wheaton etc.

For reasons of clarity, the more commonly used - three station - horizontal turret that has

been developed by Jomar over the last 40+ years will be used to describe the basic injection

blow-moulding process.


Injection Blow Tooling Parts

Jomar M15V &m20V


Melt

Split

BLOCK TYPE “VERTICAL SPLIT” “COAT HANGER”

MANIFOLDS - PLAN VIEWHeater rodor hot oil

Figure 7

Figure 6

The heart of the injection blow process is the triangular table (turret) which rotates in accurate 120º

steps via a CAMCO or FERGUSON indexing unit. A set of individual core rods are mounted on each

face of the table and are located accurately in the preform mould neck inserts to form a shut off at

the neck finish of the container. Melted plastic from the plastifier is injected via a hot manifold

(Figure 6) with individual nozzles, into the preform cavities at STATION 1, at a preset filling and

packing pressure.

The hot manifolds can be one of three main types: (Figure 7)

Solid block, with either heating rods or hot oil to maintain melt temperature.

Even filling is obtained by adjusting the orifice through each nozzle (Figure 4).

• Two Plate <Vertical Split' manifold, heated by rods or oil, with internal flow path profiling to

obtain an even output at the nozzles which will be drilled to one size.

• <Coat Hanger' type, where flow paths reduce in diameter to maintain even flow.

Each individual cavity must be filled at exactly the same instant to ensure that the heating/cooling

history within the preform is identical, so that neck shrinkage vs time is consistent and that close

tolerances can be held in the INJECTION moulded neck finish.


LOWERPREFORM

DIESET

LOWERBLOWDIESET

MANIFOLD

ENDPLATES

BASEINSERT

COREROD

2 CAVITY ROLL-ON MOLD for M15

Figure 8

Also when the bottle part of the preform is BLOWN into the finished bottle, it will inflate identically

with no wall thickness variation across the cavities.

The preform and blow-moulds (Figure 8) are mounted permanently onto diesets for quick, simple

mould changes. Hot liquid (oil or water) usually above 100ºC (212ºF) from a temperature controlled

source, is piped through the preform mould to remove heat from the injected plastic and maintain

the preform within the thermoelastic range of the polymer being processed.

After the preform has been made and conditioned the transfer head will lift the core rods vertically

from the preform mould and rotate them 120º to the blow-mould. Typically it takes 1.5 - 2.0

seconds for the moulds to open, the turret to rotate and for the moulds to close.

At STATION 2, the moulds will close around the injected neck finish, with minimal clearance to avoid

component damage and to prevent air loss. Compressed air through the core rod at 6-13 bar (90-

190 lbs/in²) inflates the preform so that the plastic will contact the wall of the blow-mould. The

blow-mould has similar drillings to the preform mould to allow chilled water at 8º-12ºC (46-54ºF)

to cool the mould. Factors such as the type and thickness of plastic used, the air pressure and chilled

water temperature, the shape of the bottle and the material that the mould is made from, determines

the time it takes in a blow-mould to produce a stabilized bottle.

When this is achieved, the mould will open and the rotary table transfers 120º to STATION 3, the

ejection station, where the finished bottle can be mechanically stripped from the core rods. The

bottles can be bulk packed straight from the stripper or transferred to a conveyor for further cooling.

If they are stood on a conveyor they can be heat treated, labelled or even filled and capped directly

from the machine.

After the products are removed from the core rods, internal and external conditioning can be applied

to the core rods prior to the start of the next cycle.


Figure 10

"D" Ø57mm 2.24"

3.3mm Wall

0.130"

35.2mm1.385"Ø

11.9mm0.468"

67.7mm2.668"

Parison Length

20.5mm0.808"

21mm0.827"

"S" thread start

1.5mm.06" Wall

I/Dia "I" 43mm1.693"

"E" Ø 46mm1.810"

"T" Ø 47.5mm1.870"

65.2mm 2.568"Core rod length

"H" neck height

R2.30.09"

R3.20.125"

2.5mm0.1" Wall

Parison Layout for 100ml Jar

Figure 9

The success of all IBM projects depends

on the correct design of both the product

and the preform. The entire preform,

including the neck form and body section,

must be contained around the core rod for

transfer from station to station without

deformation or movement. Design

limitations for round and oval containers

are discussed in detail in Section 8.

The area of the preform to be blown is

usually conditioned within the

temperature range of 150-180ºC (300-

325ºF) with a thickness of between 2 to

6mm (.08-.24"). At less than 2mm thick,

it is difficult to cure the inner (core side)

and the outer (cavity side) whilst retaining

sufficient heat to remain elastic to blow

the container. This tends to limit IBM

containers to a minimum wall of 0.6mm

(0.024"). Ultra thin containers of less than

½ mm (0.02") are therefore not feasible.

Similarly, preform thicknesses above 6mm (0.24") tend to be uncontrollable and will slow

down the overall cycle time. As can be seen in Figure 9 for the jar, additional weight is cast

around the lower part of the preform. When blown, this additional material can form itself

around the lower corner and base area to improve stability and on the lower side walls to

improve top load deformation.

By Injection moulding the neck finish, it is possible to mould solid external flanges, tamper

evident tabs and complex child resistant neck finishes for example.

The only limitation is that it has to be removed vertically from the preform mould neck

finish.

Similarly, it is possible to design features on the core rod, eg. the ball

housing for roll-ons and internal steps for talcum powder dispensers.

(See Detail “X” on CORE ROD SHOULDER BLOW drawing). These

features have to be removable from the core rod in line of stripping

as with the preform.

The internal bore of the container will be smooth and solid, with only

minor sinkage visible opposite external features such as threads and

beads.

Jomar 15-175

Section 14 - 6bPD

F Issue 1

Jomar 15-175

Section 14 - 6aPD

F Issue 1


CORE ROD2.5mm thickpreform

Blownbottle

CORE ROD

BUTTON TIP

Blown bottle witheven wall

STUDDING TO RETAIN CORE TIP

B- ADD MATERIAL IN SPECIFIC AREAS -EVEN BOTTLE WALL

A- EVEN WALL PREFORM - UNEVEN WALL BOTTLE

Figure 11

The process does require the addition of a core retention feature to capture the preform

during transfer. This can be in the form of a top annular ring or an annular bead

approximately 3mm (0.125") from the top surface which can either be an up stand or

groove on the core rod approximately 0.15mm (0.006") deep. (See Detail “X” on TIP BLOW

CORE ROD drawing)

In the case of the Roll-on core rod, the ball design acts as the retention feature.

Core rods may require a degree of taper (Figure 11), so that cold preforms can easily be

removed at start up. By reducing the core rod diameter and by tapering either the core rod

or preform cavity, it should be possible to increase the preform wall thickness to between

2.5 - 3mm (0.10-0.12"). This will increase the blow stretch ratio, make the preform easier

to fill and minimise the injection / clamping force required for the preform moulding.

In the case of long core rods, say for a 250ml cylindrical with a 24mm neck, the diameter

of the rod will reduce considerably over the length. If the wall thickness of the preform is

kept constant at 2.5mm (0.10") the blown bottle would have a variable thickness.

Any required profiling should be carried out on the preform cavity (Figure 11 lower).

In extrusion blow-moulding, it is possible to increase the wall thickness on flat ovals by

using a wide parison and compression moulding the neck with external flash. This is not

possible on IBM as the material has to be formed and transferred on the core rod to the

blow-mould without flashing.

A A B C D E F G H I J K L M N O P Q R S T1

2

3456789

10

111213141516171819

20

2122

23

2425

26

27

28

293031323334

3536373839404142434445464748495051

ISO9001ISSUE 3HOWIBMMMYELLOW CELLS ONLY TO COMPLETEJOMAR MOLD CAVITATION WORKSHEET (METRIC)- for VERTICAL PlastifiersINSTRUCTIONS- INSERT PRODUCT DESCRIPTION, MATERIAL TYPE AND SIZES ETC IN MM'S IN CELLS D4-D11. SEE NOTES G7-11 & F30-34. COMPLETE CELLS O30-O34.

17-Oct-01DATE: ??CUSTOMERJAR 100 ml - ROUND -PSDESCRIPTION OF PRODUCT:4= PVC, AN,BAREX, PC, PU, SANTOPRENE. PET3=HDPE, LDPE, PP, PS, MIPS, HIPS, SAN, ABS, K RESIN, XT POLYMER, KRATON.3MATERIAL TYPE??M85SVSERIAL N° IF KNOWNM15V, M40V, M65V, M85SV, M115, M135, M175VM85SVJOMAR MODEL

(1) For Bottles under 75mm (3") long the longest trigger bar can be used to maximise cavities.NOTES:INCH "MMSPRODUCT SIZES For bottles between 75-150mm (3"-6") long the standard trigger bar shoul be used. 2.2457E" Minor Thread For bottles over 150mm (6") long check with JOMAR for the correct option.2.5665Blow Split Dia or Major dim. "D"(2) Choose the screw to give you your shot weight (SEE BELOW)2.5665Height H(3) For PVC, Polyurethane etc using LOW COMPRESSION screws shot weight is reduced by 20%± 1 GRAM17Weight

CALCULATION A1 - PREFORM AREA for Necks of less than 32mm dia.MAXIMUM CAVITIES A1 =7.6=26581={X}mm² =Preform area available for preferred m/c and material {X}

IN PREFORM61x57"E" x (H - 4)Bottle Preform area Minor dia "E" x Parison Length (H-4mm)

ORor CALCULATION A2 - PREFORM AREA for necks of 32 - 47 mm dia.MAXIMUM CAVITIES A2 =9.0=26581={X}mm² =Preform area available for preferred m/c and material {X}

IN PREFORM 0.85x3477E x (H -4) x 0.85Bottle Preform area (Minor dia "E" x Parison Length (H-4mm) x 85%

ORor CALCULATION A3 - PREFORM AREA for necks greater than 48mm dia.MAXIMUM CAVITIES A3 =9.6=26581={X}mm² =Preform area available for preferred m/c and material {X}

IN PREFORM0.8x3477E x (H - 4) x 0.8Bottle Preform area (Minor dia "E" x Parison Length (H-4mm) x 80%

CALCULATION B - BLOW MOULD DIESETMAXIMUM CAVITIES B =8.3= 622.3= {Y}mm =Width of Dieset to suit bottle length TABLE {Y}

ON STD. BLOW MOLD DIESET10+65(Dmm + 10mm)(Max Width of bottle at "PART LINE" + 10mm)

CALCULATION C - TRIGGER BAR LENGTH - SEE NOTE 1MAXIMUM CAVITIES C1 =8.5= + 1562=+ 1{Z}mm =+1 Length of trigger bar TABLE {Z}

mm TRIGGER BAR561.98FOROR + 1065(Dmm + 10mm)(Max Width of bottle at "PART LINE" + 10mm)

MAXIMUM CAVITIES C2 =9.1 + 1609.6LONGER BARmm TRIGGER BAR609.60FOR + 1065

9.6CHOOSE FROM A1, A2 OR A3 TO SUIT YOUR NECK SIZE.REMEMBER: THIS IS A GUIDE TO MAXIMUM CAVITATION ONLY.SHOT8.3MAXIMUM CAVITIES YOU CAN GET ON A DIESETIF B OR C ARE WITHIN 0.2 OF A WHOLE NUMBER CAVITATIONWEIGHTWEIGHT8.5CHOOSE FROM C1 OR C2 TO SUIT YOUR HEIGHT OF BOTTLEMAY BE INCREASED. IF YOU HAVE MORE THAN 13 CAVITIES

grams136=17X8TAKE LOWEST "ROUNDED DOWN" NUMBER FOR CAVITATIONAND WITHIN 0.4 OF A WHOLE CAVITY YOU MAY BE ABLE TO CHOOSE SCREW SIZE FROM CHART BELOW. GO TO THE NEXT WHOLE NUMBER. ASK!!

272TYPICALLY TWICE THE SHOT WEIGHT =CAVITIES 8AND6 QUOTE FORIF IN ANY DOUBT TALK TO JOMAR!STANDARD JOMAR MACHINE VALUES ARE

Wider Dieset {Y)PREFORM AREA AVAILABLE {X}Vertical Plastifier-Shot weight HDPE in 10 seconds injection. {Z}for small bottlesStandard Diesetat PREFORM INTRUSION PRESSURE (SEE MATERIAL)

30:130:124:130:130:130:1JOMAR Trigger Bars Options on longest trigger barsfor normal bottlesHigh Low High Low JOMAR3"2½"2½"2"1.375"1"MODELOTHER LENGTHSSTANDARDmmWidthmmWidth387 kgs/cm²246 kgs/cm²5500 lbs\in² 3500 lbs/in²MODEL

mminmminmminmminmm²mm²in²in²50M15V1756.91636.40.00.0266.710.5294846454.67.2M15V

1809050M40V38715.2531112.240.00.0444.517.589681406413.921.8M40V18090 M65V6102456222.125711.228.0622.324.5121941916118.929.7M65V

360270180M85SV6102456222.125711.228.0622.324.5169032658126.241.2M85SV450360270180M115V6862791436990.639.0901.735.5260004086440.363.3M115V**450360270180M135V6862791436990.639.0901.735.5318064993549.377.4M135V450360 M175V965381118440.00.01270.050.0410326451663.6100M175V

** ASK JOMAR FOR AVAILABILITY

REMEMBER You can always ask Jomar for advice. This file is available on floppy for Excel and Quatro Pro.


CORE RODRETAINER

TRANSFER HEAD

"DUMMY” CORE ROD

CORE ROD

CORE RODRETAINER TRIGGER

or CAM BAR

O RING

CORE ROD HOLDER ASSEMBLY

Figure 12

The number of cavities that can be installed on agiven size machine depends on two main criteria:the ability to clamp the preform mould duringpacking without flashing the preform, and thenumber of blown bottles that can be fitted within theoperational centre distances on the trigger or pushbar situated in the transfer table (Fig 12).

(Also see the Jomar Cavitation worksheet for the100ml Jar and Figure 13 for more information)

Nº of PREFORM cavities = Preform clamp tonnage ofinjection blow machine

Cross sectional area of preform x packing pressure of preform

As the preform is split along the parting line, for necks under 28mm this area would equateto the blue cross hatched area on Figure 13 (Calculation A1).For larger necked containers ie jars, this area can be reduced (Red area figure 13) by theshaping of the core rod to increase the number of cavities that can be clamped withoutflashing (Calculation A2 or A3 depending on neck size).The preform pressure is based on a low pressure preform of 246 kg/cm² (3,500 lbs/in²) forLDPE, HDPE, PP, PS and a pressure of 387 kg/cm² (5,500 lbs/in²) for engineering resins,PET, PVC and PC.The CAVITATION WORKSHEET gives some idea of the various calculations on cross-sectionalarea that are made depending on the size of neck finish. The Jomar range of IBM machinescan be configured with various rotary tables and plastifiers to cover all options.Blow clamp is not usually critical unless you are blowing at 12 bar (180 lbs/in²) on verylarge containers.Nº of BLOW cavities = Blow clamp tonnage of injection blow machine

Cross sectional area at bottle parting line x blowing pressure.

The trigger (cam) bar fits snuggly inside the rotary table and is used to activate the cam nuton the core rod to allow blowing air to inflate the preform. (Fig 12).The trigger bar length activates the centre line to centre line core rods of the outsidecavities. Nº of BLOW cavities = Trigger bar length + 1 cavity

(Bottle width + 10mm (0.40"))

It is normal practice to allow 10mm (0.40") between the edges of the cavities in the blow-moulds. Calculations B and C on the cavitation worksheet will help arrive at these figures.The lowest number of whole cavities is the “probable” maximum cavitation for your Jomarmachine.You will also require a plastifier that can produce the good shot weight (number of cavitiesx weight in grams) in the actual intrusion time (see section 19). This time is typically ½ the overall cycle time for most products but refer to Jomar forconfirmation.


There are many variables that have to be taken into account in Injection blow-moulding design, thathave a major effect on the finished sizes. This is one of the reasons that Jomar make a unit or pilotcavity for most projects, before completing the production mould.The Zeigler and Phillips manufacturing processes for HDPE both produce different shrinkage ratesand preform inflation patterns. In PP, Homopolymer, Copolymer, Random and Clarified PP’s also havedifferent processing techniques and shrinkage characteristics.

MATERIAL “T” “E” HEIGHT BLOWNSIZES

HOT MELTFACTOR

grams/ml

HOT MELTFACTOR

grams/in³

HDPE 2.4-2.8% 1.8-2.2% 1.6-2.0% 1.8-2.0% 0.76 12.5

LDPE 2.2-2.6% 1.6-2.0% 1.6-2.0% 2.0-2.4% 0.80 13.1

PP 2.0-2.4% 1.8-2.2% 1.5-1.9% 1.4-1.9% 0.77 12.4

BAREX-PC 0.4-0.6% 0.1-0.4% 0.4-0.7% 0.4-0.7% 1.12 18.3

PS-SAN 0.4-0.6% 0.2-0.4% 0.4-0.6% 0.4-0.6% Refer Jomar ReferJomar

The chart above gives some indication to the shrinkage rates that can occur. However, final sizesdepend on many variables including:

Melt flow index of chosen material and manufacturing process, Colour and additives %, Screw speed(time to fill cavity), Melt temperature, Preform packing pressure, Cure time, preform mouldtemperatures, blow-mould coolant temperature, air pressure, time sitting on core rod at strippingstation, bottle temperature at stripping, time on cooling conveyor, overall cycle time, design of waterchannels and preform design to name a few. Bottles can continue to shrink for 24 hours after manufacture!

In the table above we mention the “HOT MELT FACTOR”. This figure is used to calculate the weightof plastic that will be cast in the hot preform mould during the normal cycle of the machine. It is ahot mould into which you are intruding (injecting) molten plastic and you have to take into accountthe double shrinkage that occurs in the process. Basically, if you calculate the preform volume is10ml you will end up with 7.6grams of HDPE at a density of 0.95 gm/cm³ in the bottle. Similarly 1in³ would contain 12.5 grams of HDPE.

NOTE: THE INFORMATION IN THIS DOCUMENT IS INTENDED TO GIVE AWIDER UNDERSTANDING OF THE INJECTION BLOW-MOULDINGPROCESS.IT IS A GUIDE ONLY - JOMAR TECHNICAL DESIGN ARE ALWAYSAVAILABLE TO DISCUSS YOUR PROJECTS AND TO GIVE


“E” DIA

Outside Dia "D"

RATIO 1. HEIGHT "L" I/DIA "d" =

EASY ASK

<13:1 <15:1

At high ratios the core rods can flexunder injection pressure to produceoffset preforms. (see right)

Similarly with core rods of less than 8 mm (¼") diameter Offset Preform

RATIO 2. O/Dia "D"=

EASY ASK

< 3:1 < 5:1I/Dia "d"

At 3:1 it is possible to achieveexcellent wall distribution.

As the ratio increases towards5:1, the process needs bettercontrols to guarantee even wallthickness.

RATIOS for ROUNDS

Bottle wall varies

TYPICAL JAR PREFORM

"C"

"F"

“C” is Base Push up“F” is Blow Mould Clearance = 2.5mm (0.10")

PREFORMAREA

APPROXIMATE BLUE HATCH PREFORM AREA = “E” x (“L” - “C” - “F”)JAR SIMILAR BY CALCULATION.APPROXIMATE WEIGHT OF PREFORM = TOTAL VOLUME OF PLASTIC AROUND CORE ROD X HOTMELT FACTOR. (SEE NOTES)

Figure 13

The BOTTLE DESIGN RATIOlimitations of the bottles are as follows:(Figure 13)1) Ratio 1: If the core rod length to

diameter ratio is excessive,the core rod can deflectduring injection, causinguneven wall thickness in thefinal product.

2) Ratio 2: Similarly, the material canstart to stretch unevenly ifthe outside bottle diameterto core rod diameterbecomes excessive, givingan uneven wall.

3) Ratio 3: Additionally, for oval bottles(Figure 14) it is necessary tocompare the major to minordimensions of the blowncontainer. In extrusionblow-moulding, it is possibleto compression mould theneck finish from the parison,and apply additional plasticat the major axis of theblown container.

In injection blow, it is possible to ovalize the preform, but excessive ovality will result inribbing on the minor axis and possible preform weld problems (see oval preform Figure 14).

As stated earlier, normal preform thickness would be approximately 2.5 - 6mm (0.10-.24")to retain sufficient heat in the preform between the injection and blow phase of the process.

In oval containers this can locally be increased to 8mm (0.32") before parison sag will makethe process unstable. Handled containers with cut-outs are not possible in IBM. The core rod gets in the way!The versatility of Jomar Injection Blow process is such that you can be making 20ml jars in SAN in the morning, change the mould and be making 1 litre bottles inHDPE a few hours later. Machines are designed to be very versatile with theability to change materials without changing the screw.


CORE ROD

PREFORM

RATIO 3. Major "M" Minor "m" =

EASY ASK

<2.4:1 < 3:1

At less than 2.4:1 it is possible to develop adifferential wall thickness parison which will produce an even wall thickness on the oval bottle.

Above this ratio, more wall thickness variation willoccur, but, provided it is a reasonable shaped ovalit should be acceptable up to maximum of 3:1

MinorDim"m"

MinorDim"m"

Major Dim "M"

Major Dim "M"

Note: Ratio 1 and 2 from theround drawing still apply toovals. In ratio 2, substitute Major Dim"M" for the outside diameter.

OVALISED PREFORM

ABOVE 2.4:1 WALL VARIATION

“d” Inside dia ofneck bore

5mm

8mm

WELDLINE

COLD FILLFRONT MELT

PROBLEM WITH OVALS

Figure 14


INJECTION BLOW MOULDING v EXTRUSION BLOW MOULDING1 Bottle Weight Variation 1 Bottle Weight Variation

A Approximately 1% A Approximately 3%2 Wall Thickness Distribution 2 Wall Thickness Distribution

A Uniform wall thickness A Wall thickness variation approximately 10-20%B Thick wall capabilities, but thin walls difficult to control B Both very thick and very thin wall capabilities

3 Bottle Finish, Shape, Size & Outputs 3 Bottle Finish, Shape, Size & OutputsA Superior surface finish A Poor surface finish and score lines from die and pin gap B High clarity from fully polished mould surfaces B Matt surface finish from die gap shearC Ovality Ratio limited to 5:1 C Unlimited Ovality RatioD L/D Ratio limited to 15:1 D Unlimited L/D RatioE Bottle sizes limited to 1 litre for commercial reasons E Bottle size unlimitedF Hollow handleware not possible F Hollow handleware possible

4 Neck Finish 4 Neck FinishA Controlled external and internal neck finishes with injectionmoulding tolerances

A Uncontrolled external and internal neck finishes with blow-moulding tolerances

B Fully finished neck forms B Neck finishes may require post operation5 Waste or Scrap 5 Waste or Scrap

A No scrap during production A 20% - 40% scrap during production - requiring grinding andrecycling equipment

6 Number of Cavities 6 Number of CavitiesA Greater number of cavities A Lesser number of cavitiesB Slower cycle time B Cycle times slightly quicker

7 Automation 7 AutomationA Process controlled & repeatable A Process variable B One operator for 4 - 6 machines B One operator for 1 - 2 machinesC Minimal ancillary equipment required for product handling C Extensive ancillary equipment required for product handling

8 Floor Space Efficiency 8 Floor Space EfficiencyA Machines are compact and require minimal ancillaries A Machine is compact but requires extensive ancillaries

9 Technician Input 9 Technician InputA Simple mould changes with fast setting times A Complex mould changes with longer setting timeB Predetermined & repeatable process settings requiring noadjustment

B Predetermined setting conditions, but requiring constantadjustment

10 Resin & Materials 10 Resin & MaterialsA Wide range of materials & resins can be processed A Limited materials & resins can be processed

11 Capital Costs 11 Capital CostsA Mould costs are high but with low maintenance and long life-span A Mould cost low requiring high maintenance and shorter life -

spanB Lower combined machine & mould costs for long production runs B Higher combined machine & mould cost for long production runsC Higher mould costs for short production runs C Lower mould costs for short production runsD Minimal ancillary equipment costs D High ancillary equipment costs


Figure 15

As can be seen from the above, injection blow tooling is complex and consists of 3 mainparts; the preform mould, the blow-mould and the core rods, holders and stripperattachments.

Injection clamp forces can be considered low from between 12 -200 tonne depending onthe machine size, and this is spread over the large horizontal split face of the preformmould (Fig 15). The moulds are very hot, which will ease material flow and keep the filling pressure lowcompared to normal injection moulding. However, hot material flashes very easily in a hotmould and split lines and joins have to be perfect! The preform mould consists of the neckinsert which contains the thread form, the preform cavity and end plates. The only metalto metal wearing contact in the system occurs between the core rods and the neck insertat the shut off point. These inserts are designed to be replaced when wear occurs. Preforminserts are locked into the preform mould by a rear step to retain them in place against theinjection forces. The join between the preform mould and neck insert can be used forventing, as well as the vertical face between cavities. Waterways are profiled around thepreform cavity to get a more even heat profile and to create turbulence. End plates are used to connect the water hoses to the mould. In the event of any damage, individual cavities can be removed for repair, while the restof the mould continues in production (See Section 13 - Preform Mould heating for IBM).Moulds also have to be designed around the material being processed.


Figure 16

Blow-moulds (Figure 16) consist of theneck insert, blow-mould, base insert andend plates.The neck insert is designed to be largerthat the preform insert so that thepreform can be inserted without damage.Interference could move the preform andcreate flash.The blow cavity shape is usually vapourblasted or etched for PP’s PE’s etc. toallow the air to escape. It can bepolished for PS, PC, SAN etc. Venting canbe machined carefully across the splitface to allow air to escape between thecavities. Base inserts can either be fixedfor shallow bases in PE/PP, or retractablefor deeper inserts and the hardermaterials. Without retractable bases, itis possible to distort and damage theneck finish on extraction from the blow-mould. All parts in both preform andblow-moulds will be keyed and dowelledto simplify re-assembly.

For styrenics (PS, MIPS, HIPS, SAN, ABS etc.) Polycarbonate (PC) and PET moulds haveto be fully hardened throughout. For PVC, moulds would need to be made of stainless steelor plated to prevent corrosion. For many standard packing materials (LDPE, HDPE, PP)only the injection moulding neck finish and core rods need to be fully hardened.

The rest of the moulds can be pre-toughened steel for the preform mould and aluminiumfor the blow-moulds.

Multi-cavity individual moulds (up to 32 cavities possible) are accurately installed on thedieset for handling, and machining tolerances of better than ± 0.01mm (0.0004")arerequired to stop flashing in the hot preform mould. Allowances will also be required on thecavity centres to take into account the heat expansion in the preform mould and coolingin the blow-mould.Tool manufacturing quality similar to an injection unscrewing mould is required. Core rods act as a blow - exhaust pin and are designed with either shoulder or tip blowing,depending on the material being processed and the product being made (See Figure 17 forassembly or drawings inserted earlier).

Core rods, can also be temperature controlled using oil. At 60ºC (140ºF) for PET, it allowsthe hot material to release from the core rod, and at 180ºC (350ºF) when processingpolycarbonate it helps to maintain the preform melt temperature for blowing.


Heated core rods will also reduce the time required at start up to get the core rods to theprocessing temperature. Cost of the core rods treble and the internal oil can causeinternal contamination of the preforms and this will need to be monitored continually. To achieve an even release of the preform from the core rods, a high quality polish andplating is beneficial. Many materials require the addition of a lubricant (typically zincstearate) to assist this release at high temperatures.

To totally guarantee the delivery of your project, it is essential that a fully detailedcomponent drawing is supplied prior to or with your order. If possible, start this processwhile you raise the orders and deposits.

STAGE 1. Mould Design - From receipt of Order and Product DrawingNormal time frame 7-14 days. Includes: complete design package, all mould componentand assembly details, as well as all machine interchange parts for each individual job.STAGE 2. Unit Tool Developmenta) 1 cavity will be developed ahead of the production set of tools.

Unit objective is to determine package feasibility, dimension stability and maximizequality of each individual product.In most cases the production tool is being roughed out and approximately 60%-70%completed while the unit tool is developed.Normal unit tool development time frame is 6-10 weeks from receipt of approvedproduct drawing depending on the complexity of the product.

b) Unit tool samples are subjected to an in-house QC .inspection. This report will beshipped along with unit samples for customer approval.

c) Rework to unit tool, if required, can be completed in a relatively short time frame and,once again, samples will be QC. inspected and shipped to customer for approval.


STAGE 3. Production Tool Developmenta) production mould will take from 4 -10 weeks from approval of unit samples depending

on development and approval of unit samples, incorporating the original unit tool inthe production assembly.

b) Production tooling will be sampled, QC. inspected and submitted for customerapproval.

For some simple components, where Jomar have previously made very similarmoulds for the same resin, the STAGE 2 - UNIT TOOL DEVELOPMENT program willnot be implemented. The delivery times quoted are for a simple component. Delivery times can be extended for non-round shapes, fully hardened moulds,engraving or toolmakers availability and holidays.Production tools include:Complete engineering/drawing package

Parison assembly on diesets + manifold assemblyBlow assembly on diesets3 Core rod holder assemblies completeStandard stripper assembly complete (BOSS stripper extra)3 complete sets of core rod assemblies + spare set (6 imp tool - 24 core rods)1 spare parison neck insert (if included in quotation)

Moulds are 100% machine ready, producing quality parts within product drawingspecifications and quoted cycle times at time of delivery.

COMPONENT MANUFACTURING TOLERANCES- To a drawing accepted by Jomar.Jomar will manufacture moulds to produce components to the followingcomponent drawing tolerance bands:± 0.15 mm tolerances - Full band is required for the process window± 0.25 mm tolerances - 80% band required for process ie ± 0.2mm± 0.50mm - 75% band required for mould development ie ±

0.38mm± 1 mm and above - 7 5 % b a n d r e q u i r e d f o r m o u l d

manufacture/process tolerances ie ± 0.75mm

Closer tolerances are possible. Additional mould costs will be incurred andcharged to the customer, but will not be known until after the production mouldis manufactured.


We are often asked why IBM moulds cost so much. We would like to try to explain the JOMARphilosophy on mould quality and purchase and try to explain the various options available to you.In injection blow-moulding as in injection moulding it is possible to design and manufacture mouldsin many different qualities, hardness and finishes. A mould can be designed to make 1,000,000 pieces or 100,000,000 pieces. If you are purchasing the Rolls-Royce of machines, "The JOMAR", we have to assume that youwill be wanting to produce the maximum quantity of products in the shortest amount of time withthe least maintenance and minimal labour.Now, we could produce a less expensive mould, with savings on machining and quality. But.......If it did not live up to your expectations who would be to blame? If it ran slowly with variable quality, with a lot of supervision and attention who would be to blame?JOMAR of course.

To give you, the customer, the best possible introduction to JOMAR and Injection Blow-mouldingwe ALWAYS recommend that the first mould and machine are supplied as a unit, with full trainingusing both your machine and your mould, efficiently and safely. both in JOMAR and in your plant.The moulds are a very expensive item and deserve the ultimate care. You will normally only have one mould for a product, and if it is down for any reason, you are goingto be late delivering to your customer.

If it runs below your expectations you are also going to be late with deliveries to your customer.JOMAR moulds are designed to produce the best commercial quality bottles available using thelatest and best possible design and manufacturing technology. Every part is interchangeable. Every part is checked against manufacturing specification both for sizes, hardness andfinish. Every mould comes with spare core rods and preform neck insert, and retractable blowbases (if required).Each tool package is mounted on diesets for quick mould change.All mould loop hoses are included.

AND we give you full MOULD engineering drawings so that you can make spares locally as and when required.

In fact, this is the way we recommend customers to get involved in making IBM tooling, by makingspares. You will soon learn about the close tolerances and finishes required to match the JOMARquality. (Typically ± 0.012mm or less (± 0.0005") in critical areas).

We guarantee the cycle you will run at to ± 1 sec.

We guarantee the production efficiencies when the machine is installed to the JOMAR standard.After the first or second mould from JOMAR, and with 12 months experience in IBM, there areseveral practical ways to develop your skills and reduce the mould costs.

Our recommended INTRODUCTION program is:1 Buy your first guaranteed machine and mould package from JOMAR.

TAKE THE FULL JOMAR TRAINING COURSE (After all, it is free!)


2 Buy the pilot cavity for your next mould. This would include the mould design, engineeringdrawings, and 1000 bottles developed and made on as wide a processing window as possibleto optimise conditions for your product approval and testing in your supplied resin.

You must realise that a mould has to be suitable for various suppliers resins, and not depend onhigh melt temperatures or compromised water temperatures to make thread sizes, or to controlmaterial distribution.

You can then make the rest of the mould locally and develop a relationship with a local toolmaker.

3 Your next step would be to buy the "best effort" preform design and full engineering drawingsfrom a USA IBM mould designer and make the mould locally.

4 When you have made several moulds this way and you feel confident in your knowledge of theprocess and what happens between the preform and blow-mould stage, have a go at designingand manufacturing a pilot cavity.

We will give you all the encouragement necessary to take these steps. By now you will have 2-3machines with many people trained in the process.

Next time you consider various mould quotes, please ask yourself the following questions:

1 What does the quoted mould price include? Spares (core rods & neck rings)Retractable blow-mould bases (if needed)Full component and mould drawings Loop Hoses Sampling including required rework to meet your drawing specifications1000 samples (at least) from the approved mould in your resin and colourQC inspection data Shipping etc

2 Is it guaranteed to perform on cycle and efficiency?

3 Is the tooling quality guaranteed?

4 Will I have a wide processing window to achieve my quality?

5 Will I get the assistance I need on training and starting up this and futuremoulds?

6 Do I feel confident in dealing with design negotiations, product tolerancesand material grade selection?

7 Will I have to pay for any design changes to achieve the quality I need?

If you are unsure, CHOOSE the JOMAR GUARANTEED MOULD.


Nozzle

Core rod

Preform

NeckMouldInsert

Preform/Parison MouldHot

Waterlines

STAGE 1

Core rod

Preform

NeckMouldInsert

Blow Mould

Coldwaterlines

8-10°C

STAGE 2Base insert

TYPICAL

50°C

115°C

95°C

95°C

95°C

50°C

In injection blow-moulding, the preform, and the preform mould are of great importance. The plastic moulding compound is injected into the mould (which is normally at a controlledtemperature above 100ºC), and is then cooled down to its particular thermoelastic (blowing)temperature range.

For the further processing of the preform, i.e. blowing, not only its design but, above all,temperature conditions are decisive factors. It is particularly important to equalize temperaturevariations between regions close to and remote from the gating and those due to differences in wallthickness in the longitudinal and transverse cross sections.

The purpose of this is to allow optimum biaxial stretching of the preform to produce the container.

This can be accomplished successfully if the core, and more importantly, the mould, aretemperature controlled by means of three independently regulated circuits (neck, body, base). It should however be noted that only when the core diameter is greater than 10mm can coolingchannels capable of providing effective temperature control be accommodated in the core crosssection. Reliable temperature control of the different zones of the injection mould can be provided only by

a system of circulating oil or water. The system must be capable ofboth supplying and removingheat. Cartridge Heaters provide heatingonly.Without cooling, an almost auto-thermal heat balance is set up, whichcannot be adequately controlled.

Again, in view of the required uniformtemperature control around the entirecross-sect ional areas, on lytemperature control channels orchambers which surround or followthe profile as near as possible to thepreform to ensure reliable operation.

Waterways that are not profiled will be ineffective.This applies particularly when partially crystalline plastics with their relatively narrow stretchingrange are being processed. As already mentioned, direct temperature control of cores withdiameters <10mm (0.39") is not possible. In such cases with L/D ratios up to about 10:1, a core 'flushing' or airflow system of temperaturecontrol is used. With longer cores, an auto-thermal heat balance is set up and this can createprocessing problems.

Cores with diameters >10mm (0.39") can be provided with a direct temperature control systemalthough this is not always required. For example with L/D ratios up to 10:1, a core diameter<54mm (2") and a fairly uniform preform wall thickness, it is not absolutely necessary to have aseparate core temperature control system when processing PS, HDPE, LDPE and PP.


The deciding factor here is whether with a thick-walled preform and small core, enough heat canbe supplied, and heat which has to be dissipated fully removed by conduction, radiation, andconvection, to provide a core temperature distribution suitable for stretching. Or, conversely, whether with a thin-walled preform and large core, enough heat can be suppliedto achieve this purpose. On this point, it should be noted that the required temperature distributionin the injection mould can only be achieved and maintained if the individual temperature controlcircuits do not overlap excessively and there is not a constant heat from the mould, base andmounting plates.Incorrect temperature setting is indicated when, for example, the preform is locally over-stretchedor bursts during blowing.

In extreme cases the preform may even stick to the overheated core or in the mould cavity. If the neck region is too cold, the preform is not freely released from the core in this zone with theresult that a toroidal thickening is formed inside the bottle at the transition point from the neckto the shoulder.

Not least among the factors which influence correct temperature control is the wall thicknessdistribution chosen. Problems arise if the ratio between the lowest and highest wall thickness is toogreat. The temperatures set for the core and the different mould zones should preferably correspond tothe required preform stretching temperature. This means that the melt temperature must adaptitself to these set values while the preform is in the mould. In no circumstances, however, is it permissible to shorten the residence time of thepreform in the mould by selecting core and mould temperatures far below the stretchingtemperature.

If the edges of the preform are not properly temperature-controlled, problems arise in blowing.Minor deviations from the required temperature may occur in the gating region or where there arelarge differences in wall thickness. The most advantageous stretching temperature for the preformdepends on the moulding material used and the blow up ratio employed. This temperature can be determined experimentally by producing containers with varioustemperature settings and preforming times and assessing their quality.The criteria used are; drop strength, compression and bursting strength as well as appearance(transparency, surface finish).In this way, the optimum stretching conditions are established and thus from the temperature curvefor the preform, its preforming time and hence the cycle time can be predicted.

Therefore mould temperature controllers are used to bring the preform mould toan operating temperature, and to maintain this set temperature by either heatingor cooling.The benefits are: 1. preheating the mould to the production temperature. (50-

150ºC)2 removing heat from the preform during conditioning3 optimisation of the cycle time 4 control of quality and dimensional stability on the neck

finish.


WATERPositive 1 Operating with water is more economical, cleaner and presents

fewer problems.2 In the case of leaks in the temperature control circuit (eg hose

couplings, mould leaks etc) water loss can be simply run into thedrainage system without further problems.

3 Minor leaks between cavities does not stop production.Negative 1 Water has a low boiling point (therefore needs closed system -

pressurised)2 Depending on the water quality, there is a risk of corrosion and

calcification of the system. (Temperature control unit, mould,machine heat exchanger, plastifier water jackets etc.)

OILPositive 1 Thermal oils do not exhibit the disadvantages of water as

mentioned above.2 No corrosion and calcification of the temperature control circuit.

Negative 1 Heat transfer efficiency approximately 1/3rd that of water.2 Production of odours above 150ºC.3 Higher fluid cost.4 Tendency to "cracking" and degradation in time at temperature.5 Flammable under certain conditions.6 Any leak between the moulds can contaminate the preform

and mould surface and has to be corrected. Oil is asearching medium at high temperatures!

Injection Blow RequirementNormal requirement is for 3 temperature zones for moulds up to 500ml, with anadditional zone for larger moulds set at between 50 and 150ºC (120-275ºF).Additional heater required if temperature controlled cores are used.Oil heating is recommended for core temperature control through small passages.For polycarbonate and engineering resins it may be necessary to go up to 200ºC(400ºF) where oil heating is essential.

Each heater may be controlling 3 loop lines across the preform mould (2 halves).S Heaters should have sufficient KW capacity to heat the mould and dieset

assembly to the required temperature in a short time (15 - 20 minutes). Fromexperience this in the region of 10-15kws.

S Should have sufficient flow to maintain the temperature across a multi-cavitymould at ∆t=1º. (1ºF preferred)

S After start up, mould cooling should be controlled to keep the processingtemperature at ±1ºC.


model

Aquatrol®

*Recommended for Jomar IBM & ISBM *

SEPARATE KIT AVAILABLE TO ADD PROCESS WATERAIR PURGE - SAVES LOSS ON MOLD CHANGEOVER!

SEE THE JOMAR RECOMMENDED HOT WATER INSTALLATION

Model Heater Pump Pump Voltage Amps Weight (Kw) (HP) Flow Standard

RA1820 18 2 2.87lps @ 3 bar 460/3/50-60 25 107 kgs30gpm @45 lbs/in² 235 lbs

RA1820E 13 2 2.38lps @ 2 bar 380-415/3/50 20 107 kgs

It is also possible with some heating systems to have individual control for eachline across the preform mould ie. 6 heaters for 6 lines. Again lines must be heatedup in 15 - 20 minutes and you are looking at approximately 5-7 KW per line. Once in production, all heaters maintain the temperature balance within the mould,either periodically heating or cooling as the process requires.

HosesAll HEATING hoses should be flexible - stainless steel braided.

Heavy duty 1 HP pumps provide over 100 litres per minute (25gpm) ofturbulent flow to the preform mould. Designed to operate at ± 1ºF orC it is designed for IBM with many safety features included as standard.(See separate leaflet)


JOMAR HAVE INSTALLATIONS WHERE MOLDS HAVE NOT NEEDED DIS-ASSEMBLY FOR OVER 4 YEARS.

H.E.

VENT

X

10-20ºC

CHILLER @ 8-15ºC

HE - HEAT EXCHANGER TO COOL HOT WATER FROM PROCESS HEATERS TO 20ºC OR LOWER.PUMP TO SUPPLY 1.1lps @ 3 BAR NOMINAL PRESSURE TO ATMOSPHERE THROUGH ¾ “ (20mm) PIPE.MINIMUM BACK PRESSURE OF 0.3 BAR IN THE RETURN LINE.

Hot water from preform mold

Hot water toPreform molds atbetween 40 -150ºC

Flow controlvalves

MACHINE COOLING REQUIRED FOR HYDRAULICS AND 2 PLASTIFIERZONES. DEPENDING ON THE SCREW AND MATERIAL USED, PLASTIFIER“COOLING” MAY BE RUN FROM THE CHILLER OR HOT WATER UNITS TO PROTECT SCREW MOTOR AND REDUCE MATERIAL WASTE. WATER CIRCUITS TO BE KEPT CLEAN FROM SCALE. TOWER WATER CAN BE USED IF < 20ºC AND “CLEAN”

WARNING - HOT WATER PIPES MUSTBE INSULATED -OPERATING + 100ºCCooling to

Blow Mold

Returning water to heatexchanger @ 40-100ºC

Water supply to fill circuit and providecontrol water to hot water units at ideally 10-20ºC.

Singles or 3 zone Hot Water units

Gravity headertank with de-ionised and cleancold water.

Strainer fitted in2 places.

200 Litermin tank

1 HP(min) PUMP

INDIRECTCOLD WATERTANK FORPROCESS

BYPASS

XXXX X

XX

XX

Figure 25

Water is the preferred heating medium on the preform mould, as it optimizes themachine output. However, the slightest calcification of the machine heat exchanger,preform mould water ways or the plastifier water jackets reduces the heatingcoefficient within the steel and will slow the process down or lead to plastic leaks.

Moulds can require dis-assembly in as little as 4 -6 weeks in bad water supplyareas and this could lead to premature tool wear and mis-alignment. To overcome this, we recommend the installation of a simple, indirect supplysimilar to a central heating pumped tank system as per the drawing below. It is always recommended that a filtration and water treatment unit beinstalled on recirculating systems in order to minimize corrosion and scaledeposits in the unit. Effective water treatment can only be accomplishedby a properly maintained Ion-Exchanger which will continually reduce thehardness of the cooling water, and a ph monitoring system.

"WATER TREATMENT" consisting of a quantity of chemical added periodically (evendaily) is not an effective water treatment for long immersion heater life.The only major loss from this type of installation is at mould change over and ifthere is a leak. It is possible to install an air "blow through" system to clear themould hoses and waterways through the mould. This liquid can be suitablystrained and recycled to the cooling reservoir."Top up tanks" are also used to supply pre-treated water to the cooling reservoiras required.

It is highly recommended that the Jomar machine hydraulics, plastifiercooling jackets, blow-moulds and the indirect heating system areconnected to suitable chillers to maintain the "as new" condition.


Machines can be built to suit any location in the world. In fact Jomars are already installedin over 60 countries. 1 Starting Machines are supplied with star delta as standard, but various soft starts

and wye delta configurations are available.2 Installation Many options are included as standard; Barry Mounts, Water

Manifolds, Bellows for clamp cylinders etc. We can also offer sound proofing, air intakedrains.

3 Colour New style machines are available in white. Older style machines in StandardJomar Blue. Other colours are available (ask for selection of colour plaques).

4 Processinga) The BOSS innovative system actually takes the finished bottle as they come from the

Jomar and deposits them upright, orientated and properly spaced on a conveyor beltfor additional cooling or downstream operation without any additional labour!


Whereas a standard stripper uses the blown bottle shoulder to strip the bottle from thecore rod, which can mark the bottle, the BOSS system utilizes a closely fitting neck insertthat grips the injection formed part of the bottle neck only. Note the narrow widthconveyor shown in 4 below. This should be slightly wider than the largest bottle you wantto produce.For easily marked products (polystyrene, SAN, Polycarbonate) this system can be suppliedwith vacuum cups.

b) Air Amplifiers can be supplied where air pressure is low < 6 bar (< 90 lbs/in²). Thisis capable of doubling the supplied pressure. It will optimise definition, maintain bettercontact with the blow cavity wall for cooling and give a consistent blowing pressure.

c) Rotary Unions are used mounted to the rotary table of the machine to supply heatingmedium to the core rods for applications where it is required. This could be for core rodcooling when processing PET, or for heating when processing PC. It can also be usedto improve material clarity and polish.

d) Screws, and static mixers There is a wide selection of screw designs to suit specificmaterials and static mixers can be fitted to the primary nozzle.

e) Barrel control It is possible as an option to have Ceramic Heater bands fitted and alsobarrel cooling for heat sensitive resins.

f) Tropical Machines can be supplied with tropical motors and air conditioning for hightemperature operations.

g) Clean Applications HEPA filters can be assembled to the latest machines as anoption. Also additional blow air filtration. Machines will require additional sealingaround conveyors and take offs to eliminate external contamination.

h) Water Units Jomar supply single zone water units, direct and indirect for IBM. See Section 10-12 for more details. Standard Spares package also available. (see Options)

i) Spares Jomar machines are supplied with tool kits and some spares. (Ask to see list for your specific machine)We also supply a 2 year “SPARE PACKAGE” containing many of the service and repairkits that may require changing to maintain your production.

j) Conveyors - these can be supplied to suit the BOSS or a plain takeaway conveyor.

There are other options that are fitted from time to time for specific applications. Please do not hesitate to ask your sales representative for other options available.


All standard resins (LDPE, HDPE, MDPE, PP, PS, etc.) can be processed on IBM., as well asmany engineering resins (Barex, K Resin, Acrylics, Santoprene, ABS, etc.) that have limitedcapability on EBM. Extrusion or tape grades used in the packaging industry are ideal forIBM., as the benefits of good stress cracking and drop strength are maintained or improved.

The injection moulding into a temperature controlled <hot' mould, under low pressure formost materials, produces a highly homogenous structure, that will transfer strength intothe even wall thickness of the final bottle and give increased stress crack resistance. Thepolished finish of the preform mould will also translate into a glossy, smooth surface finishon the container. The polyolefins (HDPE, LDPE, MDPE) and sometimes PP are improved by the addition of aninternal lubricant within the melt structure. Benefits are improved cycles with earlier releaseof the melt from the preform mould (hot and sticky), and an even release from the core pinon blowing will improve the even wall thickness on the blown container.

Lubricants such as Zinc stearate, calcium stearate and antistatic additives are used.Beware that these additions can remove the food and drug approval from the resin used.

As well as processing the standard homopolymer and copolymer grades of PP, moulds andmachines can be developed to process random and clarified grades for contact clear bottles.PS, which is nearly impossible to extrusion blow-mould, has for a long time been used tomanufacture a wide range of crystal clear tablet bottles in the UK and USA.

Jomar has a long list of approved materials from around the world. (See Section 8 of theJomar Manual) or ask for an up to date copy.

As part of the design and development process, we ask that all customers supply their own,locally available, resins and master batches for the mould trials. If in doubt, you arewelcome to ship any material to Jomar Corp and this will be tried on a similar mould. As importing into the US requires specific forms and details to be available with the goods,we ask that you contact Jomar Corporation first for shipping requirements.


(See Figure 1)DROPPER BOTTLES - These are usually produced in LDPE forpharmaceutical use. Using only virgin plastic, IBM machines areinstalled in clean manufacturing environments worldwide (SeeSection 19). Alternatively the products can be stripped from thecore rods whilst still very hot and carried to the clean rooms in sterile air for packing. Thiseliminates any machine or material contamination in the clean room.

INJECTABLES - These are usually PP, made by the same method as the dropper bottle, but gammaradiated or autoclaved before or after filling.

TABLET or PILL BOTTLES - These are made from PP, HDPE, LDPE & PS. These bottles can bedesigned with complicated injected neck finishes for Child Resistance or pilfer-proofing. Also theneck finish is excellent for barrier seals against moisture with a plug seal closure, and also very flatfor tamper foil application.

MASCARAS - These are made in PVC, PP, PET, HDPE. Small necks make EBM difficult. The processadvantage with IBM is the quality of the neck and surface gloss finish and ease of manufacture. PVCspecially developed for IBM can be moulded in virgin form without degradation.

LIQUID PAPER - These are made of Barex, PET (some PVC) for ease of processing expensivematerials with no scrap.

JARS - These are made in PP, HDPE, PS, MIPS, SAN etc. Jars are made in a wide variety ofmaterials. The process advantage is that no secondary trimming (scrap) is required when makingthe neck finish. Ovaloid neck (petroleum jelly) jars can be made by injection moulding the neckfinish. Multi- cavity moulds can be built to produce 16 x 4 oz jars in 10 secs in PS.

OVALS - CYLINDRICALS AND BOSTON ROUNDS - These bottles are made in HDPE, LDPE, PP.Up to 24 cavity moulds from 10-15 second cycles. QUALITY PRODUCTS do not cause problems ondecoration, filling or capping lines, and are less liable to bring customer complaint. PVC can be usedfor containers up to 200 ml only.

ONE PIECE ROLL-ON DEODORANTS in PP and HDPE. Close tolerance of injected ball seatingallows even application of product. Other materials use snap-on ball housing in SAN and PET.

BABY BOTTLES - These are made in Polycarbonate (and some PP). PC is a very expensive, difficultmaterial to process on EBM. Baby bottles made with no scrap in virgin material are made worldwideby IBM.

MISCELLANEOUS USES - Some other uses include the production of Bellows, Laboratory ware,Christmas tree balls, Light globes, Fish bowls, Flower vases and bowls, wash balls, lemons, etc


Jomar INJECTION BLOW MOULDING (IBM) machines are used in many situations around the worldby a large number of companies to make a wide range of pharmaceutical bottles and technicalmedical parts.We are also pleased to number amongst our many users, major pharmaceutical manufacturingcompanies who make bottles for their own products.

CLEAN ROOMS, CLEAN PRODUCTION, CLEAN PACKING, GOOD MANUFACTURING PRACTICE (GMP)are all descriptive of what our customers are trying to achieve. At the end of the day, it is reallyabout what your ultimate customer wants to receive in the way of clean, fault free product, madein known resin to the correct specification.

Good Manufacturing Practice is the part of quality assurance which ensures that products areconsistently produced and controlled to the quality standards appropriate to their intended use.

There are several different ways to install and operate Jomars’ in clean production.Our machines are installed in many "CLEAN ROOMS" around the world. We do not intend to get intothe discussion of for's and against's. Just to say, that, if this is your chosen method of installingJomar's, it requires discipline and creative thinking to install and manufacture continuously in thisenvironment.

Many other machines are installed at interfaces to clean rooms, or in clean production areas andthen the products are taken for packing in a clean environment.

Within the book, you will find complete details of the Jomar Model 15 and 40, CLEAN machines asshown at recent exhibitions. Most pharmaceutical production takes place on the smaller machines,but the comments within the book can easily be adapted to our larger production units.

"STERILE" - COMPLETE ABSENCE OF LIVING ORGANISMS."ASEPTIC" - ABSENCE OF KNOWN ORGANISMS THAT CAUSE DISEASE."CLEAN" - FREE FROM DIRT or CONTAMINATING MATTER.

Do not get confused between sterility, aseptic and clean!

Sterility is usually achieved by a secondary process. You could argue that bottles, blown with cleanair, are sterile at the point when the bottles leave the (very) hot core rod on stripping. However youmust immediately fill this bottle to maintain this sterility, without human intervention. This has not proven totally practical.

Sterility is achieved by gamma radiation, gas sterilisation and steam sterilisation.For gamma radiation, products are subject to radiation within the final packing. All bottles, dirt particles and bugs etc are sterilised. Everything may be sterile, but not necessarilyclean!The bottles are initially packed in a polythene bag which is then heat sealed, an irradiation dot, isplaced on the outside of this bag, which will change colour after radiation. This unit is then packed in a further plastic bag and heat sealed. The completed packs are then sealed in normal cardboard packing. Pallets of boxes are thenirradiated on specialist plant and then sent for filling. The various layers of packing are removed in various levels of clean area prior to reaching the fillingstation where the final bag is opened.


For gas sterilisation products are removed from the initial packing and in specialist plant, flushedwith ethylene oxide prior to filling.

Steam sterilisation is typically used for polypropylene, other materials will not stand thetemperatures required. This process can take place either as a washing & hot air drying before thebottle is filled or the complete filled pack is sterilized after filling.

Bottles need designing to have a rigid base to stop rocking from the internal pressure created duringsterilisation, but thin enough to allow the product to be dispensed.

Aseptic production is heavily dependent on human performance. The primary source ofcontamination in any product is human - we all shed particulate as we work and it is very difficult -even with modern gowning techniques - to prevent contamination. See Appendices for interestingarticles.

CLEAN ROOMS are covered by two accepted standards in the USA and UK: AMERICAN FEDERAL STANDARD 209EBS 5295 Part 1, 2 & 3 BOTH SUPERSEDED in 2001 by BS/EN/ISO 14644-1, -2 & 4, -3, 5 & 8 and BS/EN/ISO 14698-1, -2 & -3.EN 1822 HEPA and ULPA FiltersStandards now relate to particle counts within the production area, “as-built”, “at-rest” and“Operational”. Design of clean rooms depends on the filtration and changes of air per hour, flow pattern across thework area, temperature and humidity, lighting, number of operators, clothing, etc, etc.

In the pharmaceutical industry, accepted production requirements, local legislation and productquality set the standard required. In the medical field, bacterial contamination sets the standard.

For pharmaceutical production, laminar or uni-directional flow provides the work zone with theminimum of eddying effects which disturbs any loose particles. Horizontal or vertical "laminar" flowwill provide a CLASS 100 condition close to or under the filter but this will degrade to a class 10,000away from the filters.Filtration of the air takes place in a High-Efficiency Particulate Air Filter - HEPA filter.

“CLEAN PACKING” WITH JOMARThere are three ways of installing machines to obtain clean production (Figure 29): 1) Machines can be installed in the clean room.

Clean rooms do need continual monitoring. Problems occur with machine servicing and mouldchanging in maintaining the clean room integrity. A modified type of modular clean room is shown in Figure 2. Areas within this clean room can be closed off for maintenance.

2) The face of the machine could be at the interface and controllable from within the clean room.Additional sealing of the Jomar is required in this situation to minimise air loss and preventdraughts across the mould surfaces. The difficulty with this installation is the time lost insuitably attiring technicians and staff to service the equipment from inside and outside the cleanroom.

3) The machines can be placed away from the clean room. A conveyor can be designed to capturethe products from the core rods and transport the bottles to the Clean Packing area. (Figure 31)


FIGURE 30

CONCEPTS

1

2

3I.B.M MACHINE

CLEANROOM

AIR SUPPPLY

1) IN CLEAN ROOM2) AT INTERFACE TO CLEANROOM.3) PRODUCT PACKED IN CLEANROOM

CLEAN-ROOM

CLEAN

Figure 29

For 2) & 3) above a portable clean packing room can be used in front of the Jomar, to pack productsin. This can be a curtained, movable, clean packing area with a supply of air from a HEPA filtermounted above the packing area.

I

t is also possible to install a HEPA filter as an option on the Jomar to provide laminar air across themoulds and ejection area. Packing must take place within this air flow and environment.

See also the Collage of photos of installations from various customers around the world.


CORE ROD HOLDER

"C"

BOSS CLAMP

CONVEYORJOMAR MACHINE AREA

TO CLEANPACKING ROOM

START UP BOX

CENTRAL REJECT & START UPSEPARATOR ROTATES TO STOP SCRAPENTERING PACKING AREA. PARTS FOR Q.C. ANALYSIS CAN BETAKEN FROM HERE, USING BYACTIVATING FLAP.

55 10 10 10 10

CORE RO D HO LDER

55 10 10 10 10

BOS S CLAMP

55 10 10 10 10

5 55 5

10 10 10 10

CONVEYO R

CLEAN AIR FLOW OVERBOTTLES ON CONVEYORINTO MACHINE AREA.

"A"

"B"

"E"

"F"

"G"

10 10 10 10 10 10

SEE SEPARATEDRAWING FORPACKING

BOSS STRIPPER

JOMAR MACHINE AREA

"C"

10 10 10 10 10 10

FIGURE 31

CLEAN PACKING CUBICALWHERE ARMS CAN BE PUTTHROUGH SEALEDSLEEVE S TO GAINACCESS TO SEAL THEBAGS UNDER CLEAN AIR.

CLEAN PACKING ROOMWITH CL EAN AIRSUPPLY. AIR L OCKACCESS. COUL D BEUSED FOR SIM ILARACCESS FOR INJECTIONMOLDED PARTS.

PHOTO EYE TOSWITCH BETW EENBAGS WHENCOUNTED. ALSOROTARY BAG UNITSCAN BE USED.

PLASTIC BAGIN PL ASTICHOLDER

CLEAN PACKING CONCEPTS FOR I.B.M

TYPICAL ISOLATOR TH AT COULD BEADAPTED TO SEAL THE BAGS OFPRODUCTS TAKEN FROM TH E JOMARIBM M ACHINE.

FIGURE 32

Figure 31 shows a typicalisolator which is a cleanpacking environment, whichdoes not have to be in aclean room. Bottles can bepacked in irradiated bagsfrom the side access.

Figure 32 is a closer look atthe machine / conveyorintersection with 10mldroppers.

The BOSS system {A} canstand the bottles on the"STEPPING" conveyor. A"STEPPING" conveyor movesthe batch of bottles a shortdistance each cycle {to B},i.e. not continuous. Thisimproves cooling time on theconveyor.

A simple separator flap {E}can be used outside themachine area to reject startup bottles into a scrap boxwithout entering the packingarea {F}.

This system can also be used to take QC samples. When the bottles are acceptable the separatorcan be reset so that the bottles can now enter the clean packing room {G}. With the conveyor tightly covered, and sealed to the machine and "packing room", air can flow overthese bottles and prevent contamination and dust ingress.

Figure 33 shows a plan view of another type of installation where the bottles are leaving on aconveyor from the face of the machine to a “clean packing” isolator.


FIGURE 33

One way of installing a Jomar Model15 is shown left in plan view. It ispossible to get many rows ofcontainers cooling prior to packingwhere the BOSS is employed toplace bottles. It is useful whenpacking thick wall bottles as itallows additional cooling time.

It will be necessary to design a dropchute to allow the bottles to dropbelow the front guard and still standup on the stepping conveyor.

Bottles should be packed into cleanplastic bags. No cardboard isallowed into the packing area.

Instead of investing in cleanrooms, the bottle counting areacould be a small cubical (isolatorshown left) with side gloves toallow access for hands to seal thebags when full. With this system,no operators would be enteringthe clean room, which is themajor cause of contamination.


"INTRUSION" moulding is where the melt pressure required to fill the preform cavities iscreated by screw rotation in the vertical barrel only. There is no secondary horizontal screwor ram!

"INJECTION" moulding is where the screw itself is used to ram material into the cavity. Thisscrew and barrel are mounted horizontally. The screw can turn at the same time as it isinjecting. Additional shear heat is generated by injecting through small nozzles at high speed.

The benefits of intrusion are lower melt pressures and temperatures with consequently lessstress and lower melt temperature in the preform. The screw rotates longer to fill the cavity and therefore smaller diameter screws can beused as against those used for the same output in Horizontal Injection Blow Machines.

The screw is driven from the bottom, larger diameter end. Screws are usually 24:1 or 30:1 ratio with no loss of flights through the reciprocation of thefeed zone as with horizontal screws.

The screw FEED zone, which is vertical within the hopper is always full of plastic.No screw shut-off is required, therefore there are no potential wear parts in the screw tip.

Jomar also makes a horizontal screw machine for certain polymers and for customerpreference.

The machine is in AUTO. Both moulds are closed. At this point in the cycle the SCREW is notrotating, and there is no plastic in the PARISON Mould although the rest of the system isfilled with plastic.

With a Jomar Vertical plastifier the complete screw assembly reciprocates duringthe cycle.

Initially the HYDRAULIC HOLDING CYLINDER holds the entire PLASTIFIER unit, HEATINGCYLINDER, CARRIAGE (on rollers), DRIVE MOTOR with PRIMARY NOZZLE BODY and brassNOZZLE TIP against the mould MANIFOLD. At this time the CAM is clear of the CARRIAGE and the LIMIT or PROXIMITY SWITCH is off.

The plastic in the extruder system is decompressed and static.

This timer signals the HYDRAULIC DRIVE MOTOR to do nothing or to "wait" for furthercommand(s).This timer allows for the extension of the cycle when bottle cooling time takes longer than


parison or preform forming time. It also helps to develop more usable melt by adding to theresidence time of the material in the system.

When the "preform delay" times out, the "HIGH" and "LOW PRESSURE PREFORM" timers areactuated simultaneously.

This timer signals the HYDRAULIC DRIVE MOTOR to rotate the FEED SCREW in the counterclockwise direction. RPM's for this action are variable and input via a valve or dial for thespecific material's and mould's requirements.

The cold plastic is picked up by the FEED ZONE of the SCREW in the HOPPER and conveyeddown the flights of the screw through the COMPRESSION ZONE into the METERING ZONEwhere the nozzle port is located.

This cold plastic, being drawn into the screw when it rotates, and the flights of the screwcreate the pressure to push the molten plastic down the screw, and will eventually fill themould.Since the material is under pressure in all directions at the METERING zone, it will take thepath of least resistance wherever possible.

The nozzle port then becomes the natural path for the material.

The extrudate path is through the NOZZLE BODY and NOZZLE TIP to the MANIFOLD.The manifold is used to divide the melt into the number of impressions of the mould andallows the melt to pass through the MOULD NOZZLES and into the PARISON CAVITIES.

As the screw is rotating, a small amount of material is allowed to bleed around the bottomshank of the SCREW, in the form of powder or flake.This provides for a self cleaning, self lubricating bearing and seal. The amount that bleedsthrough is controlled by a water jacket.

Once the PARISON CAVITY, MANIFOLD, NOZZLE TIP and NOZZLE BODY fill completely withplastic, the extruder, still rotating, causes the plastic in them to pressurize.


MATERIAL HOPPER

HOPPER DRAIN

WATER JACKET COOLING HOPPER THROAT -PREVENTS MELTING OF PLASTIC IN HOPPER

HEATER BANDS

BARREL

SCREW EXTENDS INTO HOPPER

HYDRAULIC CIRCUIT

H.P. PREFORM

PRESSUREREDUCING VALVEMANUAL 4 WAY VALVE

ACCUMULATOR

HOLDING CYLINDERHYDRAULIC

SHALLOW REVERSE THREAD FORM TOREDUCE FLOW OF PLASTIC BLEEDFROM BEARING. HYDRAULIC MOTOR

DRIVE UNIT

DRIVE COUPLING

PRIMARYNOZZLE BODY

NOZZLE TIP

NOZZLE CLAMPAND ADJUSTERS

FEED SCREW

SAFETY STUDS

CARRIAGEROLLERS

CARRIAGEGUIDES

SPLIT

ADJUSTABLE POSITION LIMITSWITCH TO STOP SCREW WHENCAVITIES ARE FULL

WATER JACKET TO PROTECT MOTORAND REDUCE BLEED OFF

TYPICAL PLASTIFIER ASSEMBLY

MANIFOLD

PREFORM MOLD

NOZZLE

CAM

COMPLETE PLASTIFIERASSEMBLY MOVES

Figure 34


This pressure is also realized around the last flights of the screw and adjacent area of theinside barrel wall.The continued influx of plastic into the nozzle and mould system eventually causes theplastic pressure in the system to equalize with the hydraulic holding pressure in theHOLDING CYLINDER.

The holding pressure is variable to suit individual moulds and material requirements withthe PRESSURE REDUCING VALVE.

On M40 machines and above two "INTRUSION" pressures are available:- HIGH PRESSURE, with its own timer is used to increase the oil pressure in the HOLDINGCYLINDER at the start of filling, to ensure mould nozzles open, prevent "double pumping"of the plastifier assembly and to move the molten plastic easily before the pressure dropsto:LOW PRESSURE, which is used to minimize stresses and to pack the preform without flash

When the internal plastic pressure overcomes the holding pressure of the cylinder, the entireextruder assembly, (hopper, screw, barrel, base, motor and nozzle body only), moves back,on the carriage rollers, causing the telescoping joint to start to "SPLIT".

The plastic pressure will hold the brass NOZZLE TIP against the MANIFOLD and in place.

The still rotating screw intrudes more plastic into the nozzle causing the split to increase andfurther moving the extruder back (5 - 10mm). But.........

Before the extruder can move back to separate the NOZZLE BODY from the NOZZLE TIP,the CAM trips the LIMIT or PROXIMITY SWITCH, cutting the signal to the DRIVE MOTOR andstopping the screw.Now the holding pressure in the cylinder and the plastic pressure in the mould are equal atthe pre-set pressure.

The remaining time on the low-pressure preform timer is used to pack this cushion ofmaterial in the SPLIT nozzles into the preforms and to stabilize them.

If this cushion of plastic disappears and the cam comes off the limit switch, thescrew will rotate momentarily and the nozzle will split again. This is called"DOUBLE PUMPING".

When the "low pressure preform" timer times out, the "cure" and "decompress" timers areactuated simultaneously.


Both of these are actuated at the same time, but only the cure time controls the cycle.The decompress timer signals the DRIVE MOTOR to reverse rotate the screw in a clockwisedirection (usually only one or two turns).

This action reverses the direction of the material flow, putting some unplasticised pelletsback into the hopper, relieves the holding pressure in the NOZZLE BODY and allowing theholding pressure in the CYLINDER to push the extruder assembly off the cam. This closesthe SPLIT by moving the entire assembly back into the original position.

The last bit of decompress depressurizes the MANIFOLD and MOULD NOZZLES, preventingnozzle drool.

The "cure" timer (timing along with, but independent of, the "decompress" timer) allows theparisons to orient to the proper conditioning and blowing temperature before the mouldsopen.Upon completion of the cure time, the moulds open, the parisons transfer, the moulds closeand the "preform delay" timer is activated again, repeating the entire process, accurately,precisely and efficiently.

NOTE: With Jomar Vertical plastifiers, the screw is driven from the largerdiameter, preventing possible screw shear. The live bearing at theplaten level, although cooled with a water jacket is designed toallow a small amount of plastic chips and flakes to pass through,and be collected in the supplied bag which will require emptying.This waste material can also be collected in a vacuum type cleaner.

REMEMBER The output of this type of screw is greater than a horizontalrecipro-screw of the same diameter, and therefore, less energy willbe required on the vertical plastifier for the same shot weight ofplastic.


GUARD SPAREPARTSHOPPERETC

MOLD

Figure 35

A Machine Shipping & UnloadingJomar machines are designed to be moved using suitable fork lift trucks with an extended

reach on movable skates., or by overhead lifting. Please let Jomar when you order your

machine how it will be installed and we will supply suitable drawings and instructions.

Only suitably trained personnel should be employed to move the Jomar machines.

Instructions for lifting will be included and some additional assembly will be required to

complete the machine build.

Machines can be delivered as follows:

1) In USA on low loader

2) Crated (additional cost)

3) 20 or 40 ft Container.

Figure 35 shows a typical

container and the packing

of the various parts.

Ideally the container should

be unloaded at a loading

dock. If no suitable dock is

available the container can

be lifted to the ground for

unloading.

B. Installation

All machine sizes will require the lifting and fitting of the plastifier assembly which

is usually supplied in a separate crate. This weight is as quoted on the installation

specification and depends on size. The Model 40 and 65 require safety gate

installation and the connection of safeties. New generation machines 85S-175 are

supplied requiring minor gate assembly and cabinets rotated into position. The

accumulator and alarm lamps are removed for shipping.

Full instruction drawings are supplied with your machine detailing space required,

utility requirements and instructions to complete the machine installation. This will

be supplied at the time of ordering.


Available for each machine size is a set of installation drawings and installation specifications

similar to the next insert. This will list the service requirements for your project. Additional

items to be purchased from Jomar or locally are:

A TO IMPROVE MACHINE INSTALLATION1 CONVEYOR for product removal.

Small products can be taken from the machine straight into the final shipping

container. However, the retained heat within the bottle from the process, will take

many hours to dissipate and continued shrinkage of the product and distortion may

occur.

The Jomar recommendation is to install a conveyor. This allows the bottles to have

further cooling during the transfer time and can enable you to operate at faster

cycles. The conveyor should be approximately 300mm wide (12") for products

dropped at random or if using the Bottle Orientation System, BOSS supplied by

Jomar, the conveyor should be say only 100mm wide (4") to suit the maximum

diameter of bottle that you want to produce. This conveyor can have flaming or

labelling attachments, or be used to count bottles to individual boxes with an

automatic box changer.

In injection blow moulding, it is normal for companies to employ 1 packing operator

for 3-5 machines.

2 HOPPER LOADER AND MASTER BATCH BLENDER

With the hopper attached to the plastifier which moves with the filling and

decompression of the mould every cycle, weight mounted at the hopper should be

kept to the minimum. If hoppers and master batch dosers are required to be

mounted on the machine they should be supported. Jomar Corporation will supply

details of the gantry required.

An alternative is to use a floor mounted day bin with master batch doser and convey

the product using a vacuum or screw system to the machine hopper. This enables

mixing quantities to be easily monitored and colours changed.

3 WATER HEATERS are discussed in Section 13-14


B EQUIPMENT REQUIRED FOR SAFE PRODUCTIONThe following list of equipment simplifies and provides a safer working environment.

a) Hydraulic Mould lift or tool trolley (weights based on maximum cavities)

Moulds require installation horizontally up to approximately 1 metre (40") above

floor level.

- Preform mould for a M15 weighs approx. 80kg 180lbs

- Preform mould for a M40 weighs approx. 180kg 400lbs

- Preform mould for a M65 - 85S weighs approx. 350kg 770lbs

- Preform mould for a M135 weighs approx. 550kg 1,200lbs

- Preform mould for a M160/175 weighs approx. 800kg 1,760lbs

b) Fixed platform or stable climbing platform for access to hopper.

The hopper for the vertical plastifier is approximately 2.5 metres above the floor for

the Model 15 to over 4 metres for the Model 175.

c) Adequate toolbox - Wrenches, Allen keys, jacks, bars etc. (some are supplied with

your machine

d) Safety wear -hot gloves and arm protectors, protective clothing, ear and eye

protectors, safety shoes etc as mandated by your company.

To maintain a correct and properly safe machine operation, it is essential that

EVERYONE working on the machine either as an operator, maintenance or service

person READS THE OPERATING MANUAL, completes a FULL TRAINING PROGRAM

and behaves in a responsible manner required when operating fully automated

process machinery.

Safe machine operation therefore depends on having :

A- Read and understood the OPERATING MANUAL. Access to the Jomar Manual must be

available at all times.

B- Full training and understanding of ALL of the machine functions.

C- Knowledge and understanding of the dangers when processing plastics, including safe

use and control of melt temperatures and other related hazards.

D- A safe working environment for yourself and others by use of responsible handling and

operating practices. CLEAN UP ALL SPILLS!

E- Full knowledge of all safety devices and on how to stop the process in an emergency.

Knowledge in the safe use of all of the isolating valves and devices for shutting off fluids,

pneumatics and for isolating the electrical power.

F- The correct clothing and using safety devices as mandated by your company.

It is the users responsibility to have all personnel associated with the operating,

maintaining and servicing of the Jomar equipment to be fully trained in their

specialised discipline, ie. Electrician for electrical, mechanic for hydraulics and

mechanical etc.


Persons involved with the operation of the Jomar Injection Blow moulding machine should

be adequately trained for their particular level of involvement which may be considered as

three standards of training :

Machine Minder - Operator. A person trained to remove and pack product and monitor

quality standard. Should be trained and capable of stopping the Jomar machine cycling in

a safe mode either under normal conditions or in an emergency.

Machine Technician - Setter. A person trained in all aspects of the machine functions and

operations including a background in aspect of plastics processing. Further supported by

specific training on the functions and operation of the Jomar machine.

Maintenance Technician - Engineer. A person skilled in either or both mechanical and

electrical engineering and further supported by specific training on the functions and

operation of the Jomar machine.

is

Whilst general training for the basic machine operation will be carried out at the customers

plant, it is Jomars experienced recommendation that all technician training for first time

buyers should be carried out at our training school situated in Jomar Corporate headquarters

in New Jersey USA.

The Jomar, fully equipped classroom environment, allows for the most concentrated and

intense training possible, without distraction from the usual day to day demands that are

unavoidable, during customer in-house training.

Training will either be co-ordinated with your equipment under construction and/or on a

similar machine in our R&D laboratory.

Training is comprehensive in all phases of machine/mould set-up and operation and also

includes basic electrical and hydraulic trouble-shooting. Additional training at your facility is

supplied with machine and mould purchases. At this time our process technicians will review

with your personnel all aspects of mould/machine set-up and operation.

We also run throughout the year, basic and advanced training courses of a weeks duration

both at Jomar and in your plant. Details available on request.


All Jomar supplied machines are built as robust work horses, and designed to give

many years of trouble free operation. However, simple machine maintenance

oversights often cause many problems to the mould and machine operation.

1 Check Water Quality

The whole of the Injection Blow process is about water. See Sections 13

and 14. Jomar cannot stress highly enough, that a simple expense

BEFORE even attempting to run the Jomar machine will pay for itself

time and time again.

With the high water temperatures required for the process, the water quality

should be checked regularly. Mineral-laden or pH neutral water can clog

strainers, machine heat exchangers, machine cooling jackets and lead to

premature tool dis-assembly and wear.

2 Oil Cleanliness

Oil contamination is one of the most common reasons for poor machine

performance and premature component failures. All hydraulic oil should be pre-

filtered to 3 microns before adding it to the system. This may seem very low,

but why not take the opportunity of filling at the best level possible. Sample

analysis should also be carried out by a suitably qualified laboratory every three

months. This analysis should check for both insoluble particulates and for

chemical structure.

Do not change oil by date or by machine hours. Oil should only be changed when

the laboratory report says so. Why empty a system and run the risk of

introducing contamination.

As an added security, it is a good idea to fit an electrostatic oil filtering system

to support the machine*s built-in unit. These electrostatic filters are so effective

in removing insoluble contaminants that users will often see machine

performance improve immediately following installation.

3 Air Supply

Ensure that your air supply clean, dry and oil free. The Jomar machine is

designed to be oil free to prevent contamination of the product.

4 Check Cabinet Filters

Modern Electronics systems are designed to run cool. Clean ALL filters regularly

and replace as required.


5 Lubricate Diesets

Mould Diesets require lubrication every 24 hours. It is a good opportunity to

visually examine the mould area, look for material leakages, mis-blown bottles,

loose connections etc.

6 Inspect Heater Bands and Thermocouples

Regular expansion and contraction of heater bands during operation tends to

loosen them off. This can lead to shorts, blown cards and damaged controllers.

A simple check on the ALL heaters once a month is all that is required.

7 Preform Nozzle

Leakage will occur between the steel primary and secondary brass preform

nozzle. The short nozzle is designed to be replaced on a regular basis as it wears.

8 Plastifier

Check the plastifier motor for leakage or movement. Leakage will signify that the

lower water jacket is becoming blocked and requires cleaning! Movement of the

screw will indicate that the bearings require replacing.

9 Accumulators.

Slow or sluggish machine movements indicate that accumulators may need

charging.

Never overcharge. (See Jomar Manual Section 3 and 9)

10 Be Safety Conscious

All safety devices must be working correctly. Check thoroughly every shift.

Clean up all material spills and leaks. Ensure after servicing or mould changes

ensure that the machine area is clear of tools and mould parts. Make sure hoses

cannot snag.

11 Be alert

No matter how many routine checks are laid down in your operating procedure,

things can and will still go wrong. An experienced operator can often detect a

sudden change in the sound or feel of a machine. So use that expertise. Stop

the machine EARLIER rather than too late.

JOMAR INJECTION BLOW MACHINE RANGE - SPECIFICATIONS 2011 EDITIONCASTING AREA (1)

CASTING AREA (2)

8" (203.2mm)7.10" max

4" (101.6mm)(180.3mm)

8" (203.2mm)8.00" max

4" (101.6mm)(203.2mm)

8" (203.2mm)

4" (101.6mm)

9" (228.6mm)

10" (254mm)

5" (127mm)

10" (254mm)

6" (152.4mm)

10" (254mm)

material processed.(7) TYPICAL CAVITATION listed are approximate and will depend on neck size, bottle size -shape and

FULL SPECIFICATIONS & INSTALLATION DRAWINGS ARE AVAILABLE AND WILL BE SENT WHEN REQUESTED.See Jomar Injection Blow in Jomar Headquarters , PLeasantville NJ USA

June 2011Issue 6

TYPICALSCREW OPTIONS (4 & 5)STANDARDROUNDSCREW DIAMETER " & mms - L:D = SCREW LENGTH : DIAMETER SHUT HEIGHTTRIGGERBLOW PREFORMJOMAR

CAVITATIONV= SCREW OUTPUT GRAMS/10 SECS R= GRAMS/SECPRESSBARCLAMPCLAMPMODEL(7)STROKE(3)

7 x 5ml3.1 Tons7.2in² @ 3500 lbs/in²12.6 Tons6 x 10mlV - 1" (25.4mm) Dia - L/D 30:1 - 50 grams HDPE - GP Screw@ 2000 lbs/in²46cm² @ 246kgs/cm²@ 2000 lbs/in²Ibm15V4 x 30mlV - 1" (25.4mm) Dia - L/D 30:1 - 40 grams PVC - LC Screw(2.8 Tonnes4.6in² @ 5500 lbs/in²(11.4 Tonnes

2 x 100ml@ 141 kg/cm²)29.7cm² @ 387kgs/cm²@ 141 kg/cm²)

8 x 5mlDESIGNED TO PROCESS SMALL PET BOTTLES4.5 Tons10.3 in² @ 3500 lbs/in²18 Tons6 x 10mlV - 1.125" (28.6mm) Dia - L/D 27:1 - 60 grams HDPE - GP Screw@ 2865 lbs/in²66.4cm² @ 246kgs/cm²@ 2865 lbs/in²Ibm20V4 x 30ml(4.1 Tonnes6.5in² @ 5500 lbs/in²(16.33 Tonnes

2 x 100ml@ 201.4 kg/cm²)42cm² @ 387kgs/cm²@ 201.4 kg/cm²)

14 x 5mlV - 1" (25.4mm) Dia - L/D 30:1 - 50 grams HDPE - GP Screw12"6.6 Tons21.8in² @ 3500 lbs/in²38.2 Tons12 x 10mlV - 1.125" (28.6mm) Dia - L/D 27:1 - 60 grams HDPE - GP Screw(304mm)@ 2700 lbs/in²141cm² @ 246kgs/cm²@ 2700 lbs/in²Ibm40V 8 x 30mlV - 1.375" (35 mm) Dia - L/D 30:1 - 90 grams HDPE - GP Screw17" max(6 Tonnes13.9in² @ 5500 lbs/in²(34.6 TonnesIbm40SR

6 x 100mlV - 1.375" (35 mm) Dia - L/D 30:1 - 72 grams PVC - LC Screw(431.8mm)@ 190 kg/cm²)90cm² @ 387kgs/cm²@ 190 kg/cm²)

16 x 10mlV - 1.375" (35 mm) Dia - L/D 30:1 - 90 grams HDPE - GP Screw21.75"17 Tons29.7in² @ 3500 lbs/in²52 Tons12 x 30mlV - 1.375" (35 mm) Dia - L/D 30:1 - 72 grams PVC - LC Screw(552mm)@ 2700 lbs/in²192cm² @ 246kgs/cm²@ 2700 lbs/in²Ibm65V

8 x 100mlV - 2" (50.8 mm) Dia - L/D 30:1 - 180 grams HDPE - GP Screw5" (127mm)25.75" max(15.4 Tonnes18.9in² @ 5500 lbs/in²(47.2 TonnesIbm65SR 3 x 500mlV - 2" (50.8 mm) Dia - L/D 30:1 - 144 grams PVC - LC Screw[10" with 4" str.](654mm)@ 190 kg/cm²)122cm² @ 387kgs/cm²@ 190 kg/cm²)

R - 2" (50.8 mm) - L/D 25:1 30 grams/sec - GP Screw HORIZONTAL RECIPROCATING SCREWIbm65R

16 x 30mlV - 2" (50.8 mm) Dia - L/D 30:1 - 180 grams HDPE - GP Screw21.75"17 Tons41.2in² @ 3500 lbs/in²72.1 Tons12 x 100mlV - 2" (50.8 mm) Dia - L/D 30:1 - 144 grams PVC - LC Screw(552mm)@ 2700 lbs/in²266cm² @ 246kgs/cm²@ 2700 lbs/in²Ibm85SV 8 x 250mlV - 2.5" (63.5 mm) Dia - L/D 24:1 - 270 grams HDPE - GP Screw25.75" max(15.4 Tonnes26.2in² @ 5500 lbs/in²(65.4 Tonnes 5 x 500mlV - 2.5" (63.5 mm) Dia - L/D 30:1 - 360 grams HDPE - GP Screw(654mm)@ 190 kg/cm²)169cm² @ 387kgs/cm²@ 190 kg/cm²)4 x 1 litreR - 2.5" (63.5 mm) - L/D 25:1 41 grams/sec - GP Screw HORIZONTAL RECIPROCATING SCREWIbm85SR

18 x 100mlV - 2.5" (63.5 mm) Dia - L/D 24:1 - 270 grams HDPE - GP Screw36"28 Tons77.4in² @ 3500 lbs/in²135.4 Tons16 x 200mlV - 2.5" (63.5 mm) Dia - L/D 30:1 - 360 grams HDPE - GP Screw(914.4mm)@ 2850 lbs/in²499cm² @ 246kgs/cm²@ 2850 lbs/in²Ibm135V12 x 500mlV - 3" (76.2 mm) Dia - L/D 24:1 - 450 grams HDPE - GP Screw41" max(25.4 Tonnes49.3in² @ 5500 lbs/in²(123 Tonnes8 x 1 litreV - 2.5" (63.5 mm) Dia - L/D 24:1 - 216 grams PVc - LC Screw(1041mm)@ 200 kg/cm²)318cm² @ 387kgs/cm²@ 200 kg/cm²)

R - 3" (76.2 mm) - L/D 25:1 60 grams/sec - GP Screw HORIZONTAL RECIPROCATING SCREWIbm135R

32 x 50mlV - 2.5" (63.5 mm) Dia - L/D 24:1 - 270 grams HDPE - GP Screw44" 32.2 Tons100in² @ 3500 lbs/in²175 Tons20 x 200mlV - 2.5" (63.5 mm) Dia - L/D 30:1 - 360 grams HDPE - GP Screw(1117.6mm)@ 3275 lbs/in²645cm² @ 246kgs/cm²@ 3275 lbs/in²Ibm175V14 x 500mlV - 3" (76.2 mm) Dia - L/D 24:1 - 450 grams HDPE - GP Screw6" or 7"49.25" max(29.2 Tonnes63.6in² @ 5500 lbs/in²(158.8 Tonnes 10 x 1 litre 152.4/177.8mm(1251mm)@ 230 kg/cm²)410cm² @ 387kgs/cm²@ 230 kg/cm²)6 x 2 litreR - 3" (76.2 mm) - L/D 25:1 60 grams/sec - GP Screw HORIZONTAL RECIPROCATING SCREWIbm175R

(6) LARGER MOTORS ARE AVAILABLE FOR ENGINEERING MATERIALS ON LARGER SCREWS - ASKCASTING AREA (1) - USED FOR HDPE-PP-PS TYPE MATERIALS for calculating maximum cavitation.

CASTING AREA (2) - USED FOR ENGINEERING RESINS for calculating maximum cavitation(3) TRIGGER BAR - ALTERNATIVE LENGTHS AVAILABLE FOR SOME MACHINES -ASK

(8) SR = STANDARD RESINS ONLY PE, PP, PS ETC(4) V = VERTICAL PLASTIFIER R = HORIZONTAL RECIPROCATING PLASTIFIER(5) ALTERNATIVE SCREWS ARE AVAILABLE TO SUIT SPECIFIC MATERIALS.

TRIGGER (CAM) BARCORE RODHOLDER

DUMMY CORE ROD

CORE RODRETAINER

TRANSFERHEAD

CORE ROD

O RING

CORE RODHOLDERCORE ROD HOLDER ASSEMBLY

HOW TO SIZE A MACHINEThere are 2 main design features that decide how many cavities of a particular bottle can be made on any size Jomar IBM machine. 1 The preform clamp tonnage. The preform cavities

are designed to contain the required amount of plastic to produce the finished article. The thickness of the preform and the material being processed dictate the holding pressure required to fill the cavity. This figure, multiplied by the cross-sectional area of the preform along the vertical axis through the neck section divided into the machine tonnage will indicate the number of cavities. Typically the holding pressure varies between 250 -400 kgs/cm² (3,500 - 4500 lbs/in²), depending on the material processed. Illustration below shows the cross-sectional preform for a typical jar.

2 The second feature is the length of the trigger bar used in the rotary transfer head to open the corerods to blow the bottle at the blowing station. For this calculation, take the outside diameter in thecase of a round bottle, the major axis for an oval bottle or the width across the split line + 10mm(0.4") to establish the cavity size of the blow mold. This dimension divided into the length of thetrigger bar + 1 cavity gives the number of bottles that can be fitted on the blow station dieset. The specification sheets give the standard lengths of trigger bar available.

However, it is possible to manufacturealternative length trigger bars for non-standard components. Contact Jomar for details.

Drawing at upper right shows a typicaltransfer head layout.

You will also need a plastifier that canproduce the shot weight required in theexpected cycle time.

The lowest number from above will be thenumber of cavities that can be made onthe size of Jomar IBM machine.

Parison Layout for 100 gram jar.

"D" Ø57mm 2.24"

3.3mm Wall

0.130"

35.2mm1.385"Ø

11.9mm0.468"

67.7mm2.668"

Parison Length

20.5mm0.808"

21mm0.827"

"S" thread start

1.5mm.06" Wall

I/Dia "I" 43mm1.693"

"E" Ø 46mm1.810"

"T" Ø 47.5mm1.870"

65.2mm 2.568"Core rod length

"H" neck height

R2.30.09"

R3.20.125"

2.5mm0.1" Wall

USMetricStandardPreformStandardPreform

Trigger barClampTrigger barClampJomar mmsTonsmmsTonnesModel6.4"12.616611.4M1512.0"38.230434.6M40

21.75"5255247.1M6521.75"72.155265.4M85S

36"135.4914.4122.9M13544"1751016158.9M175

TYPICAL MAXIMUM MOULDCAVITATION FOR JOMAR IBM

1 2 3 4 5 6 7 8 9 10 11

1) Nº of Cavities dependant on INJECTION AREA, BLOWN BOTTLE SIZE& RESIN GRADE selected.

2) Weight is typical for these type and qualityof products.3) Alternative resins can be used for these products4) Cycle depends on services available.5) “T” =THREAD diameter.

ModelModelModelModelModelModelWEIGHTCYCLE"T"MATERIALSIZEPRODUCT

17513585S654015± 1 gm± 1 secmmRESINVOLUMEDESCRIPTION

3428201812639.514LDPE5-10mlDROPPER1

3226181610549.514 20 ml

242014128369.524HDPE30 mlTABLET or2

2016101062101028 90 mlBLAKE

262012129381020HDPE50 mlSMALL3

242012862111120 100 mlCYLINDER

201812128371033PP/SAN25 mlROUND4

2016101072101138 50 mlJARS

262012108310121"HDPE60 mlROLL-ONS5

22201286212121" 100 ml

201812106291033PP/HDPE75 mlMEDICAL6

20161085111.51233 120 mlROUNDS

16128851181260PP/HDPE100 gmSINGLE7

12115631261377200 gmWALL JARS

864210381589450 gm

181610651181248PP/HDPE100 mlSPICE8

12106420281348250 mlCONTAINERS

1084220381560400 ml

181610881141224PP/HDPE100 mlOVAL9

14106440261428250 mlTOILETRY

128421-20381628400 ml

16148540221428PP/HDPE250 mlROUNDS10

14126430321528500 ml

10843205017331 litre

12106430171338HDPE250 mlLIGHT JUICE 11

1084320271438500 mlBOTTLES

TYPICAL INJECTION BLOW PRODUCTS:

DROPPER BOTTLES - Usually produced in virgin LDPE. Jomar IBM machinesare installed in clean manufacturing environments worldwide. The bottles can bestripped from the core rods whilst still very hot and transported to the clean room insterile air for packing. 10ml Droppers 6 cavities on M15 - up to 34 on a Model 175.

INJECTABLES - Usually PP and treated in the same way as the dropper bottle.They are usually gamma radiated or autoclaved before or after filling.

TABLET and PILL BOTTLES - These are made from PP, HDPE, LDPE and PS. These bottles can be designed with complicated injected neck finishes for ChildResistance or pilfer-proofing. Also the neck finish is excellent for barrier sealsagainst moisture with a plug seal closure, and also very flat for tamper foilapplication.

MASCARAS - These are made in PVC, PP, PET, HDPE. Small necks makeEBM difficult. The process advantage with IBM is the quality of the neck andsurface gloss finish and ease of manufacture. PVC specially developed for IBMcan be molded in virgin form without degradation.

LIQUID PAPER - These are made of Barex, PET (some PVC) for ease ofprocessing expensive materials with no scrap.

JARS - These are made in PP, HDPE, PS, MIPS, SAN etc. Jars are made in awide variety of materials. The process advantage is that no secondarytrimming (scrap) is required when making the neck finish. Ovaloid neck(petroleum jelly) jars can be made by injection molding the neck finish. Multi- cavity molds can be built to produce 16 x 4 oz jars in 10 secs in PS.

OVALS - CYLINDRICALS AND BOSTON ROUNDS - These bottles aremade in HDPE, LDPE, PP. Up to 24 cavity molds from 10-15 secondcycles. QUALITY PRODUCTS do not cause problems on decoration, fillingor capping lines, and are less liable to bring customer complaint.

PVC can be used for containers up to 200 ml only.

ONE PIECE ROLL-ON DEODORANTS in PP and HDPE. Closetolerance of the injection moulded ball seating allows an evenapplication of the deodorant product. Snap-on ball housings are also used on SAN and PET bottles used forclarity.

BABY BOTTLES - These are made in Polycarbonate (and disposableones in PP). PC is a very expensive and difficult material to process onEBM. IBM uses mainly virgin material and saves on waste!)

MISCELLANEOUS USES - Some other uses include the productionof Bellows, Laboratory ware, Christmas tree balls, Light globes, Fishbowls, Flower vases and bowls, wash balls, lemons, etc.

IBto MMCMaTd CcT12345678

911 Tbab

PET and INJECTION BLOW MOLDING (IBM)

M MACHINE - The Jomar range of standard Injection Blow molding machines from the Model 40 the 175 with a vertical plastifier can easily be modified to process PET.

OLDS - Typically cost 15-20% more than standard Injection Blow molds for the same product. olds are produced of steel and beryllium copper of the highest finish. ore rods are temperature controlled to " 1°C using a water or oil controlled heater. anifolds are designed specifically for PET to improve base cosmetics. These will require the ddition of a 4/8/12/16 zone temperature controller for the manifold. ypically numbers of cavities for a Jomar Model 65 will be 8 x 50 ml, 6 x 75ml or 4 x 100ml epending on the neck finish.

OLORING - Liquid colors have been beneficial on tinted and clear bottles to improve gloss and larity. These have been added using a peristaltic pump. Master batches can also be used. he machine demonstrated at the NPE 2000 exhibition in Chicago was ) Basic Jomar Model 85S Injection Blow machine with vertical plastifier ) Screw 2 ½" (63.5mm) PET screw - 200 grams in 10 secs ) Fan shrouds and controls for barrel cooling ) Rotary union for core temperature control ) Boss type ejector for additional bottle cooling and to prevent damage. ) 2 Thermalcare water units for preform mold and 1 oil unit for core rod cooling. ) 10 zone Hot runner controller by Athena Corp, USA (8 utilised) ) DENISON electronic speed control to maintain an

even melt output. ) PET Drier supplied by Comet Automation 0) Conveyor supplied by Carlisle Machinery 1) High pressure air system

he Jomar 85S Injection blow molding machine shown atottles “D” in 10.5 seconds at 17 " 0.5 grams in Kodak mber 5214A. Could be made on Jomar IBM at 14 grams.ottles and jars made by Jomar are shown on the right.

Jomar Model

MASCARA “A”

LIQUID PAPER “B”

50 gra“

Thread 14 mm 14 mm 29 O/Dia. 18 mm 17.5 mm 50 Height 74 mm 57 mm 41

M15 2 4

M40 8 12

M65 10 16

M85S 14 16

NPE2000 was making 8 x 75ml pill Eastman PET. White was 9921 and the Typical PET injection blown mascaras,

m Jar C”

75ml POT “D” 100ml Cylinder “E”

mm 38 mm 24 mm mm 44 mm 44 mm mm 85 mm 106 mm

0 1 0

2 3 4

3 5 6

4 8 8

A B C D E

T E C H N I C A L B U L L E T I N Processing PET on injection blow molding machinery.

Injection blow molding of hollow containers from thermoplastic material is a well proven and established process. To date there are many Injection blow molding machines throughout the world, successfully processing a number of grades of HDPE., LDPE., PP., PS., ABS., SAN., PC., PVC., BAREX, and many others. PET is well established in the production of blown hollow containers for carbonated drinks and oils etc up to 5 litres, the majority being produced using, single and two stage Injection stretch blow machinery. The Injection Blow system can be considered as a faster and more efficient process in the production of smaller, heavier containers particularly for the cosmetic and toiletries markets. METHOD PET has a glass transition temperature of about 73°C. with a re-crystallisation range extending up to 134°C. Crystallisation develops in proportion to the time during which the material is within this zone, the crystallisation rate being greatest at between 115°C to 127°C. Clear transparent bottles are blown when the PET melt is above the softening temperature but below the re-crystallisation temperature and time span. In current ISBM processes the PET preform is cooled quickly to a temperature well below both the glass transition and softening temperatures. The preform is then transferred and temperature conditioned or reheated, above the softening temperature in order for the preform to be blown. The preform is then again transferred and mechanically stretched just prior to blowing to improve the physical properties of the product. With Injection Blow, the preform is injection molded and conditioned with a core and cavity that is temperature controlled. After a specified dwell, the preform is removed from the mold and transferred on the core rod to the blow mold and inflated by air. The blown form is then transferred and ejected for packing. After the first initial cycle the process is simultaneously producing preforms, blowing and ejecting. OPERATING REQUIREMENTS Special considerations must to be taken when processing PET on Injection Blow. 1. PET is hygroscopic and must be dried to less than 0.02% H2O. The use of a closed loop desiccant bed

dehumidifying dryer and heated hopper loader is required. 2. PET must not at any time be left idle in the barrel for more than a few minutes as it is possible for the

screw to seize and for the material to deteriorate. In the event of a machine stoppage the screw must be kept rotating or the barrel must be emptied. When stopping the machine for long periods the barrel should be emptied and purged using LDPE.

3. Cooling and conditioning services must be maintained including tooling fluid channels. Any loss or

deficiency will result in severe sticking of the PET to the tooling. Fluid channels throughout the tooling and particularly within the cores should be cleaned regularly. Indirectly fed water temperature controllers supplied with de-ionised, strained and treated water is highly recommended.

4. Tooling is of a high surface finished and chromed. Mold surfaces should be kept clean and polished at all

times. 5. An air pressure of 20 bar (300 lbs/in²) has proved sufficient when blowing PET.

the ibm book

Documents

jomar page

injection blow molding

ibm page

injection blow moulding

injection blow process

processes page

injection blow moulds

typical injection