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Nairaland Forum / Nairaland / General / Business / Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling (4779 Views)
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Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 10:01pm On Oct 02, 2017 |
Hello out there! I will i be talking on Polyethylene Terephthalate processing and recycling in the next few days. |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by atesunate16(m): 12:21am On Oct 03, 2017 |
seated |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by possibilita(m): 5:41am On Oct 03, 2017 |
Yea |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 7:14am On Oct 22, 2017 |
Morning! After the brief break, I will use the next few days to talk on the major aspects and their detailed explanation. The following will be the major topics : 1. Processing Technique for bottles 2. Specific method {Injection stretch blow moulding} 3. Materials and Equipment 4. Stretch blow moulding 5. Machine types 6. Bottle design considerations + IML (In Mould Labelling) 7. Machine details 8. Mold details 9. Processing details 10. Quality Control N.B: All contributions and questions are welcome pertaining to the topic. Courtesy: CREDO NG TECH. SOLUTIONS CREDO NG ©2017 1 Like
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 11:59am On Oct 24, 2017 |
BRIEF INTRODUCTION PROCESSING TECHNIQUE Generally, in the production of hollow containers, blow moulding is the processing technique utilised. There are two major types of blow moulding which are: 1. Extrusion blow moulding 2. Injection blow moulding. The first method is commonly used for the production of polyolefin containers ( bottles, kegs, et cetera). In the production of PET bottles , a variant of the second processing technique is utilized which is injection stretch blow moulding. This is a two stage process which involves injection moulding of preforms and RSBM ( Reheat stretch blow moulding ) of preforms. The first stage involves injection moulding of preforms into a carefully designed form in an injection moulding machine. Preforms are of major types based on thread differences which are: 1. ROPP 2. PCO The injection moulded preforms are then conveyed to the injection stretch blow moulding machine where it is fed automatically or manually through the feeding section. The preforms move through an oven with multi stage infrared heaters after which the preforms move into the blow mould for blowing into the final product which takes the shape of the mould. In manufacturing processes, the most economical method or sets of method are of priority so as to lower the cost of production. This processing technique is highly economical to adopt and advantageous for small scale startup because: 1. it requires less tooling cost, 2. one stage can be capitalized on before further expansion (either injection moulding or Reheat stretch blow moulding). 1 Like
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 12:25pm On Oct 24, 2017 |
TECHNICAL DETAILS ( PART ONE) From this stage on, I will get a little bit technical with my explanations and I will always upload pictures of pieces of equipment I mention at any stage also with materials being processed with their end products (finished articles) N.B. This thread is meant to serve EDUCATIONAL PURPOSE . Also to reiterate, all questions & CONSTRUCTIVE contributions are welcome. Feedback is not left out. AIM: To wet the appetite of readers and encourage its replicability on a small scale ( both processing and recycling) Thanks. MATERIALS AND EQUIPMENT MATERIALS AND GRADES Polyethylene terephthalate material are of different grades which sometimes based on the degree of polymerization or copolymer content. Different grades serve different purposes. For example, the grade used in the production CSD (carbonated soft drinks) bottles is different from that used in the production of bottles for table water, beverages, pharmaceutical packaging materials. Common products around are: Jade and Relpet from India, Ramapet from Indorana here in Nigeria. Virgin resin is sometimes mixed with available regrind( granulated PET bottle or preform waste) which is used in the production of preforms Colour concentrates are the major additives used in production process due to the good intrinsic properties of PET as an Engineering thermoplastic polyester. Different colours used are: Amber, PET white, PET green, Water blue. The clear ones takes the natural colour of PET. Common one around is from Sarsoli colours, here in Nigeria. #pictures here show the virgin resin, bag of PET material, regrind and regrind mixed with resin for production of preform Thanks.
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by Mekanus(m): 2:22pm On Oct 24, 2017 |
Ride on bro. Following. 1 Like |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 12:58pm On Oct 26, 2017 |
EQUIPMENT 1. injection moulding machine ( There are a lot of this in Nigeria. Common ones are Ferromatik Milacron PET series and CSD ). The injection moulding machine comes mostly with its auxiliary equipment as a complete unit. Examples of such are drying silo, mould heat remover, material loader or hopper. The volumetric dosing cylinder ( for colour concentrates) is separately obtained. 2. injection stretch blow moulding machine (The common ones are: Aoline AL SERIES, Smargon, CSD and manual). 3. Auxiliary equipment include: High pressure and low pressure compressors, water chiller cooling tower ( only needed in the case of injection moulding machines) Pictures of Ferromatik, CSD, material loader, complete unit and blowing machines from CSD, SMARGON AND AOLINE, water chiller and compressors( LP and HP) are shown below 1 Like
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 1:19am On Nov 02, 2017 |
Equipment cont'd 1. Water chliller, automatic stretch blow moulding machine, complete unit of an injection moulding machine bottles coming out of a blow mould 1 Like
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 1:35pm On Nov 02, 2017 |
The first stage of production of bottles which involves the injection moulding of PET preforms. MATERIAL HANDLING The material is loaded through a hopper into the drying silo at a temperature of 180°C to reduce the moisture content of the PET material for some hours. After which it is released into the hopper of the injection moulding machine. INJECTION MOULDING MACHINE The injection moulding machine is sized based in various factors such as the clamping force, plasticating size of the barrel, injection screw diameter. These are factors that determine mostly the cost of procurement and the The clamping force is used in sizing a suitable mould to be utilized. The size of the mould has a linear relationship with the number of cavities present. The moulding period remains the same irrespective of the number of cavities and the distinguishing factor is the shot size. The ejector sleeves of the mould which has the threading determines the type of preform produced PROCESSING DATA In moulding of synthetic polymers into desired articles, the properties of the polymeric material of concern determines the processing data PET material is processed between a temperature of 318 to 298°C in the injection barrel of the machine. This data comes mostly with the machine manual and the installers handle this part mostly Clear preforms are produced without the use of master batch while coloured preforms are produced with the use of volumetric dosing cylinder containing the master batch attached to the hopper. The first stage of production of bottles which involves the injection moulding of PET preforms. MATERIAL HANDLING The material is loaded through a hopper into the drying silo at a temperature of 180°C to reduce the moisture content of the PET material for some hours. After which it is released into the hopper of the injection moulding machine. INJECTION MOULDING MACHINE The injection moulding machine is sized based in various factors such as the clamping force, plasticating size of the barrel, injection screw diameter. These are factors that determine mostly the cost of procurement and the The clamping force is used in sizing a suitable mould to be utilized. The size of the mould has a linear relationship with the number of cavities present. The moulding period remains the same irrespective of the number of cavities and the distinguishing factor is the shot size. The ejector sleeves of the mould which has the threading determines the type of preform produced PROCESSING DATA In moulding of synthetic polymers into desired articles, the properties of the polymeric material of concern determines the processing data PET material is processed between a temperature of 318 to 298°C in the injection barrel of the machine. This data comes mostly with the machine manual and the installers handle this part mostly Clear preforms are produced without the use of master batch while coloured preforms are produced with the use of volumetric dosing cylinder containing the master batch attached to the hopper. Pictures of clear and green preforms
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 5:00pm On Nov 02, 2017 |
The Injection moulded preforms are conveyed to the blow moulding station. Reheat Stretch Blow Moulding This is the second stage of the processing of producing PET bottles. It involves the reheating of the initially produced preforms by feeding on the mandrel of the machine which is powered by a rotary wheel. The preforms move through multi stage infrared heaters ( this is used in new injection stretch blow moulding machines ) while the older versions (manual) use frequency heaters. The preform is heated to attain its orientation temperature ( point of plasticity) before it is finally blown into the desired shape of the mould. |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 5:29pm On Nov 02, 2017 |
TECHNICAL DETAILS PART TWO The earlier part was to give a brief info about the whole process. This remaining part will be on STRETCH BLOW MOULDING of PET preforms to bottle. I believe anyone that understands this part can startup a small scale PET bottle production company by buying PET preforms from companies out there to produce bottles. There are some fundamentals which anyone that wants to undertake this must understand. I will be explaining that thoroughly without using too much technical terms. Your questions are welcome. Also contributions from people in the industry are also appreciated |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by WebSurfer(m): 7:28pm On Nov 02, 2017 |
Nice thread Thank you. Around how much would it cost to get these facilities? |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 11:16am On Nov 03, 2017 |
WebSurfer: This will be addressed a later time when we get to sizing and costing |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by WebSurfer(m): 12:36pm On Nov 03, 2017 |
generalstingz:ok |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 7:23am On Nov 12, 2017 |
Morning |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 2:56am On Nov 17, 2017 |
MACHINE TYPES Semi Automatic Linear Shuttle type And Rotary machines |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 4:06am On Nov 19, 2017 |
Morning |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 9:20am On Jan 01, 2018 |
Happy New Year! |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 5:00pm On Jan 03, 2018 |
Hello everyone! After a long break, I will resume ASAP on the topic of discussion. |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by pacharles1(m): 10:53am On Jan 22, 2018 |
generalstingz:Thank you so much for the info you’ve shared so far. Do you have a contact phone number or email I can reach you through. Much regards Bro. |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 3:23pm On Jan 22, 2018 |
pacharles1: 08064791246 |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 2:28am On Feb 04, 2018 |
Morning to you all! After a long break, I will continue our discussion from where I stopped. The picture below shows a semi automatic reheat stretch blow moulding machine. It has the reheat compartment apart while the blowing compartment is also apart. In the processing of a PET preform using this method, the PET preforms are placed on the mandrel ( preform jig; it appears white in the picture below). The heat data is also set according to the grams. After enough plasticity ( orientation temperature) has been achieved, the preform is then transferred to the other section which is majorly controlled by two knobs ( the opening and closing of the blow mould) in blowing process. The 3rd picture shows a high pressure compressor with the air filter connected to it.
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Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 7:25am On Feb 05, 2018 |
Morning to you all ! Have a wonderful week ahead |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 11:37am On Mar 08, 2018 |
Morning |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 11:11am On Mar 09, 2018 |
Morning! |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 12:51pm On Mar 23, 2018 |
Hello everyone! The topic will be further treated as a whole in the coming days. |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 7:32am On Aug 10, 2018 |
Morning! |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 10:08pm On Dec 10, 2018 |
Hello! |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 7:27am On Dec 21, 2018 |
Morning! |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 4:14pm On Dec 21, 2018 |
The tutorial will take its full form soonest. I will like us to click like to show our interest in the topic. 2 Likes |
Re: Polyethylene Terephthalate (PET) Processing ( Preforms and Bottles) & Recycling by generalstingz(m): 12:52am On Jan 01, 2019 |
Happy New Year ! |
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