What is PET (PolyEthylene Terephthalate)

PET (also named PETE) is a kind of polyester material for fiber, injection molded parts, as well as
blow-molded bottles and jars. Special grades are offered with the required properties for the different
applications.

PET is linear thermoplastic (long-chain molecule consists of repeating units shown as figure right),
white but bluish resin made from terephthalic acid and ethylene glycol through poly-condensation.
PET is supplied by the resin manufacturers in the form of small pellets, each about 0.05 gram. PET
came into prominence in the 1950s as a textile material. Its strength, temperature tolerance and
wear-resistance made it an ideal replacement for, or addition to natural fibers such as silk, cotton and
wool.

It has good antiosmosis, low water absorbability and good toughness. PET film's tensile strength is similar with aluminum film's, and is three times that of PC
and PA film. PET film is transparent. It's tensile strength can reach 1/3~1/2 of steel's if dealed by oriented draw. It's the toughest thermoplastic film. It will be
burnt with yellow flame and will burst when burning. And it will continue burning when away from fire.

Bottle Grade PET

Nowadays PET is still widely used for these purposes, but when, in the 1970s a marketing need was identified for larger
light-weight, unbreakable bottles to contain carbonated drinks, PET fit the bill perfectly. Unlike simple polymers such as
polyethylene, PET is not made by a single stage process, but by the reaction between two chemicals, purified
terephthalic acid (PTA) and ethylene glycol (EG). The availability of the first of these has dictated the supply of PET resin
in the past, but new capacity coming on stream this year will ensure more than adequate supplies to meet the growing
uses of PET over the coming years. Related polyesters are polybutylene terephthalate (PBT) used mainly for engineering
applications, and polyethylene naphthalate (PEN). The latter offers significant performance improvements over PET,
particularly in terms of barrier properties and heat tolerance. Since PEN can be blended with PET a range of new 'alloys'
is becoming available for special packaging applications.

As PET (bottle grade) is a kind of transparent, wear-resisting and corrosion-resisting plastics with high strength and
smooth finish, it is widely used for PET bottles of mineral water, juice, edible oil, pharmaceuticals, cosmetics, etc.

 Melting Temperature: 254-2560C

 Crystallinity: >=45%
PET products can be made crystallizable or non-crystallizable through controlling crystallization temperature and cooling speed. Usually it's crystallinity
is 0~50%. The higher IV value, the slower crystallization speed.
The key factors that effect PET bottles' molding process and performance are crystallization and orientation. If PET’s moisture level is high, hydrolysis
will happen while molding and it's IV value will drop which means products' quality be affected.

 Carboxyl End Group: <=20mol/t

 Acetaldehyde: <=3ppm (Ex-Work, related to drying & molding temperature)
For CSD bottle, <=9ppm required; for mineral water, <=4ppm required.
 Density: 1.38~1.40g/mm3
 Glass Temperature: 820C

In the bottle industry, the length of the PET chains is usually described by the resin IV (Intrinsic Viscosity). Bottle grades have IV values of about 0.65 to 0.85
dL/g, or about 100-155 repeating units per chain.
Most bottle grades of PET are copolymers, which means that a few percent of a modifier has been incorporated into the polymer chain. Copolymers are easier
to injection mold because the crystallinity behavior is improved.

A remarkable transformation takes place when injection molded PET is stretched at the right temperatures and to the right extent. The long chains undergo
strain-hardening and strain-induced crystallization, which gives the properly-made PET bottle exceptional clarity, resistance to internal pressure, uniform wall
thickness, toughness, and a host of other features. To achieve these useful properties, however, care must be taken in choosing the right grade of resin, as
well as the right preform and bottle designs, and good molding practices.

Some grades of PET have other modifications to improve the bottle barrier properties, the reheat characteristics (for two-stage systems), or the generation of
AA (acetaldehyde).

Main Advantage of PET

 Crystal Clear
Products look good, pure and healthy. Sparkling PET bottles attract attention. Brilliant glass-clear presentation of your products.
 Pure
Products taste good. PET complies with international food contact regulations.
 Safe
PET bottles are tough and virtually unbreakable during production, storage and transportation. If they do fail, they split, not shatter. Their high impact
and tensile strength makes them ideal for carbonated products.
 Good Barrier
The low permeability of PET to oxygen, carbon dioxide and water means that it protects and maintains the integrity of products giving a good shelf life.
PET also has good chemical resistance.
 Lightweight
10% weight of an equivalent glass pack, PET bottles reduce shipping costs by about 30%, and because the material in the wall is thinner, shelf
utilization is improved by 25% on volume compared to glass. High strength, low weight PET bottles can be stacked as high as glass.
 No Leakage
Absolute closure integrity is possible because of the injection molded neck finish. The absence of a weld line in the base means that PET bottles don't
leak.
 Design Flexibility
Suitable for containers of all shapes, sizes, neck finishes, designs and colors.
 Recyclable
Excellent environmental profile due to single material. Used PET bottles can be washed, granulated into flakes and reshaped as PET bottles or employed
as material for strapping, carpeting, fiber filling, etc. Specially designed thick-wall bottles can be washed, refilled and reused. PET is made from the
same three elements (carbon, oxygen, and hydrogen) as paper, and contains no toxic substances. When burned, it produces carbon dioxide gas and
water, leaving no toxic residues.
 Good Resistance
PET offers the best chemical resistance performance of any mainstream polymer used in packaging today.
 Long Shelf-life
Very good shelf-life performance, especially with the new higher barrier formulations.

Select the Right Grade of Resin -- Different Resins for Bottles of Different Purpose

Although general-purpose grades are available, as in all walks of life the best results come from a product specifically adapted for its role.

The fact that PET is used for such a variety of packaging items ? from soft drinks to cosmetics ?demonstrates how the qualities of the resin must match the
standards needed to keep the product preserved and safe for travel. Not only does the product need to be maintained in good condition, but it also needs to
sell. For that reason, the drink or food item and its packaging must be attractive, sensible and convenient. The resin chosen for a certain PET application has to
fulfil the requirements of the end product. Strength, clarity, barrier performance and UV resistance are only a few of the factors to be considered in packaging.

Homopolymers and copolymers are both used in PET resins. A homopolymer is PET containing only ethylene glycol and terephthalic acid repeat units which
results in the highest melt point and the best strength properties possible. A copolymer is PET containing additional monomers, such as isophthalic acid, to
disrupt the polymer chains, resulting in a lower melting point, slower crystallisation and improved clarity particularly in heavy wall applications.

Different grades of resins are appropriate for different end uses. Their specific qualities make them ideal for the product which they have been designed to
package. What qualities of PET are important? As mentioned above, the qualities that are important depend very much on the product for which the bottles is
destined:

CSD -- Carbonated Soft Drinks

Strength: The resins in PET bottles used to package carbonated soft drinks need very specific qualities. The material must be
extremely strong to contain the internal pressures of CO2 without distortion or expansion. This is obtained by using a resin
which has high IV and lower copolymer levels.

Clarity: Clarity is an important aspect of drink packaging in terms of consumer acceptance. A low level of crystallisation is
needed to achieve clarity.

Colour: Although one of the key qualities of PET is that it can be used as a perfectly clear material, with soft drinks this
property is not essential as many soft drinks themselves are coloured, while clear soft drinks are packaged in coloured PET
bottles.

Water -- The Clear Story

Some waters are packaged in exactly the same bottles as carbonated soft drinks and would therefore carry many of the same
requirements, but some vary.

Strength: Unlike carbonated drinks, the bottle filled with still water needs only enough strength to hold water and to survive
impact. IV requirement is reduced to the .74 to .76 range in most cases.

Colour and Clarity: Clarity is one of the most important reasons why PET is used for packaging water. PET used in water
bottles needs to be very clear and maybe even slightly blue in colour. A resin with higher levels of copolymer adds to the
clarity.

Purity: Because water is a flavourless product, having a plastic that remains tasteless and odourless is imperative. In general
terms PET doesn’t affect the taste of the product it protects and therefore is a key material for packaging water.
Juice -- Hot Fill Qualities

Juices and many other products such as sport drinks or other high acid drinks are hot filled into PET bottles. In these cases the
package is heat set in order to improve the temperature resistance of the container. PET resins with a higher Tg (glass
transition) temperature and/or a faster rate of crystallisation are preferred. Generally lower levels of copolymer are preferred
and IV’s of about .80 are acceptable.

Strength and colour/clarity: This factor is not as important with juices as CSD’s or water. The purity factor is important, as
juices would contract the taste of the plastic bottle if not pure enough.

Beer -- A New Market with New Requirements

Beer is often seen as an extension of the CSD market, but also often requires heat fill and barrier qualities. Because the
technologies used to make beer bottles are varied and the applications differ (cold filled or pasteurised), finding a common denominator is difficult. Making a
bottle to meet the desired requirements has been the most important factor. The types of PET beer bottles typically used are: non-tunnel pasteurised, one way
tunnel pasteurised and returnable/refillable bottles.

Barrier: Beer needs higher performance in both CO2 and O2 barriers compared to PET used in CSD applications. The level required depends on the type of
beer, container size, distribution channels and environmental conditions (storage time, temperature and humidity levels). Improvements in barrier properties
can be obtained via coatings, creating mutli-layer bottles and scavengers.

Colour, clarity and UV protection: Beyond the barrier properties, most beers also need to be protected from UV light. Protection can be obtained via
colorants or UV additives, which can be added to the PET at the injection stage. Because of the varied requirements for beer, resins must be chosen which
provide an adequate barrier, UV protection and clarity.

Strength: Beer bottles do need strength in order to maintain the CO2 pressure over a wide range of temperatures including pasteurisation. IV’s in the .80 to
.84 range are normally favoured. Beer bottles also tend to use champagne bases rather than footed or “petaloid? bases. In all of the above cases, the resource
efficiency of PET - due to its light weight - is one of the essential reasons why it is used with these consumer drink products. Not only does the consumer
benefit, but the transportation costs and energy consumption in delivery are decreased due to its weight. Because PET bottles are so much lighter than
alternatives, a truck can carry 60% more of the beverage and 80% less packaging ?a fuel saving of 40% and less air pollution.

To Produce PET Preform/Bottle

Traditionally PET bottle molding machines could be divided into two categories - those using the One-Step "hot preform" method and those using the Two-
Step "cold preform" method.
The One-Step method -- from PET granule to finished bottle -- all processes are completed on one integrated machine. This means the injection-molded
preform is withdrawn from the injection cavity while still hot enough to be stretch blown to form the bottle. No extra heating is required, and since preforms
are not stockpiled to be blown at a later date, but are freshly molded every time, there is no risk of surface damage from preforms knocking together during
storage or transportation. One-Step method is highly suited to small and medium scale production lines.

The Two-Step method uses two separate machines. The preform is injection molded on the first, then reheated and blown on the second. The Two-Step system
uses two separate machines: an injection molding machine for making the preforms, and a reheat blow molding machine to reheat the preforms from cold and
blow the bottles. The requirement for a preform heating system means the Two-Step process has a lower thermal efficiency. This method is most suited to
medium to large-scale production.

Usually 2-stage method is adopted to produce PET bottle.

 Drying of PET
PET absorbs moisture from the atmosphere. This must be removed by a dehumidifying drying before processing.
 Plasticizing the PET
Dried PET pellets are compressed and melted by a rotating screw.
 Injection Molding the PET Preform
Molten PET is injected into the injection cavity and cooled rapidly to form a “preform? (The test-tube-like form from which
bottles are blown is known as a preform).
For more information, click here.
 Heating the PET Preform
The temperature of the preform is adjusted to the correct profile for blowing.
 Stretch Blow Molding the PET Container
The hot preform is simultaneously stretched and blown (thereby orienting the crystals of and strengthening the PET*) into a
shaped blow mold to form a tough, lightweight container. PET that is heated to a temperature where its chain-like molecules are
sufficiently mobile to uncoil instead of breaking when extended, can be oriented by stretching. Stretching applied from two directions
at right angles, as in stretch blow molding, gives biaxial orientation. Oriented PET contains closely packed chains aligned in the directions
of stretch. The material is stronger because the molecules act together instead of individually. The tensile strength of oriented PET is several
times that of the unstretched material and the impact strength, barrier and chemical resistance are also significantly improved, so bottles can be lighter
without sacrificing performance.
For more information, click here.
 PET Container Ejector
The finished container is ejected.

Acetaldehyde Level

What is Acetaldehyde? Acetaldehyde (AA) is a compound that exists naturally in many citrus fruits and other foods. It has a distinctive acidic taste.
Acetaldehyde is also generated during the process of PET bottle manufacture.

How Acetaldehyde affects the product? With the growing popularity of PET containers, water companies are becoming more aware of AA and how it can
affect product taste. In most cases, the flavour of AA is barely detectable during beverage consumption. Carbonated soft drinks, for example, have very sweet
or tangy flavours that mask the slight taste of the plastic. But the very delicate, or even imperceptible, taste of pure water is not strong enough to mask
acetaldehyde, and so it is easier for the consumer to notice the presence of AA. Consumers rank taste as the number one criterion when selecting a water
brand. They look for purity that cannot be found in tap water. Water companies retain customer loyalty by delivering consistent, high quality products that fulfil
the brand promise. Even minor differences in taste will compromise brand integrity and affect sales.

How is AA generated in PET bottles? During bottle manufacture the resin pellets are dried and melt-processed at high temperatures (higher than 2600C)
and are injection moulded into preforms. The preforms are then reheated and stretch-blow moulded to form a container. It is during the melt-processing stage
that AA is generated.

Optimization of the molding conditions by way of minimizing melt temperature and residence time can aid in minimizing AA generation. However it
cannot be entirely eliminated. AA produced during processing is retained or trapped in the polymer matrix of the bottle or container. Since AA boils at below
room temperature, it eventually migrates out of the PET into the atmosphere or into the packaged contents, affecting taste. The amount of AA that migrates is
directly related to storage time and temperature. There are a number of ways that AA levels can be significantly reduced so that taste is not affected. The first
step is choosing the right PET resin. Resins are available with properties that are specifically tailored to the needs of water containers. For example, Voridian
Aqua PET resins 18696 and 20837 are considered leaders in low AA levels. Each has a low intrinsic viscosity (IV) of 0.72 and 0.76 respectively. The low IV
minimizes AA generation during melt-processing.

Because bottle performance is important, these resins are designed so that the low molecular weight does not compromise mechanical properties of the
finished bottle.

Certain water markets seek AA levels that are lower than even the most progressive polymers will allow. In these cases, the low AA resins are combined with
an AA “scavenger? AA scavengers are blended with the PET as it is melted in the injection-moulding phase. The scavenger reacts or combines with AA to
‘lock?it into the polymer matrix so that it cannot migrate into the product. Scavengers can further reduce AA levels in preforms up to 70-80%.It is important to
choose a PET solution with the proper balance between low AA levels and high performance. This can yield a bottle with excellent mouldability and optical
qualities. A low-AA resin should blend well with colors and tinters to produce a package with the look and feel that supports the brand.

To Recycle PET

PET is fully recyclable where facilities exist. It is given the recycling code 1. Post-consumer recycled PET (PCR PET) can be used for clothing and
carpet fiber, and fiberfill for stuffing articles such as pillows. Recycled PET can be used to make new bottles for non-food products such as cleaning
products. To make food and beverage containers out of PCR PET, it must pass through approved processes to ensure it has no contaminants, and it
must retain enough of the original properties to meet the final quality requirements. For more information about recycling PET, check out the
NAPCOR website at www.napcor.com.

A simple recycle method popular is to only crush mold PET products, then mix crushed PET granules into virgin PET resins, but the percentage should be no
more than 20%. High regrind proportion will cause variance on melt's viscosity, color and odor. Hopper magnet is suggested in injection machine when using
recycled material.
PET Preform Injection Molding

PET Preform Processing:

 Dry and dehumidify PET material -- autoloader, hopper dryer & dehumidifier;
 Melting PET material into preform mold -- PET injection molding machine;
 PET preform cooled down and formed in the preform mold -- preform mold, hot runner temperature controller, water chiller, cooling water tower.

Solution

Drying and Dehumidifying of PET

PET is a kind of moisture absorption plastics, usually its water content is about 0.05%. To get perfect PET preform (transparency and physical performance),
also to enhance molding efficiency, the water content of PET resin should be <=0.005%. Therefore necessary drying of PET is required.
The common drying methods:

 By oven:
A kind of outdated and laborious drying method. Oven is apart from injection machine, dried PET is moved into the hopper of injection machine
manually, and un-dried PET is moved into oven manually too.
As LVPET may get damp and caking while drying, only oven drying method can be used for LVPET so that it can be turned over for 2 to 3 times during
drying. The thickness of PET in the trays can be about 50mm. If dried material is not used up, set oven's working temperature to 1100C to keep it
warm. PET should not be stayed in oven for more than 8 hours, or it will deteriorate. Cooled material should be dried again.
 For LVPET, luster will appear when it is being dried. And the luster will disappear when drying finished.

 By Hopper Dryer
Most common and economical method to dry PET. If works together with autoloader, PET will be loaded into hopper dryer and dried continuously and
automatically.

 By Dehumidifier
Efficient but costly drying method, works together with hopper dryer and autoloader. It dries PET in a closed loop system to reach dew-point of at least
-320C, thus to exhibit the optimum physical performance and surface finish of PET products.

Drying Temperature
Drying target is to get moisture level <=0.005% (at the same time, AA level should be strictly controlledto avoid peculiar smell in the drink)
The best drying temperature and time are decided by IV value of PET resin. But generally speaking, it should be 150~ 1700C for about 4 hours.
If dried PET contact air with relative humidity 35~40% for 12 minutes, it's moisture content will reach 0.005%. Long-time drying will reduce its IV value. So it
is better to shorten drying time. Drying time should not exceed 7~8 hours.

Cooling of Preform Mold

Cooling of preform mold is also very important. It affects preform's quality directly. The temperature of cooling water should be 15~200C, and the pressure of
cooling water should be around 5Bar. Water chiller is suggested.

Mold Temperature

For injection machine, temperature of nozzle and front zone should be about 2800C, and middle zone around 2820C, rear zone around 2750C. The
temperature of hot runner in preform mold should be around 2700C.
These temperature vary a little bit with IMM, preform's design and weight, mold's structure and cooling, etc.

PET Bottle/Jar Stretch Blow Molding

PET Bottle Processing:

 Heat and soften PET preform -- heater;

 Blow high pressure air into preform and form bottle -- stretch blow molding machine, blow
mold, air compressor, air purifier.

Stretching blow molding is also called biaxial orientation blow molding. It is a kind of package
container producing method stretching preform in axes by mechanical device and in radial
by compressed air ( air should be cleaned by air purifier if necessary) when material is under
high elasticity condition. This is widely used for PET, PE, PVC and etc.
Orientation can improve product's mechanical property, solvent resistance, transparency and anti-
permeability. Polymer molecule is unbalanced long-chain structure. Orientation happens when stretching.
Orientation means molecule arrange along stretching direction parallelly.
Stretching blow molding brings biaxial orientation effect to the products. To cool products quickly means high
orientation degree.
The glass transition temperature of PET is 820C, and its best orientation temperature is 1050C.

Solution for PET Bottle/Jar Blow Molding

PET Stretch Blow Molding
PET stretch blow molding machine is a kind of container making method that stretches PET preform in axes by mechanical device and in radial by compressed
air when PET preform is under high elasticity condition.
Orientation can improve products' mechanical property, solvent resistance, transparency and antipermeability. Polymer molecule is long-chain structure which
is unbalanced. Orientation happens when stretching. Orientation means molecule chains arrange along stretching direction parallel.
Stretching blow moulding brings biaxial orientation effect to the products. To cool products quickly means high orientation degree. So to reach satisfactory
orientation effect, we can raise stretch speed, increase polymer's molecular weight or lower stretching temperature.
In orientation molecular chain can move freely along pulling force temperatures for four different materials.
Best Orientation Glass Transition
Material
Temperature (0C) Temperature (0C)
PET 105 82
PVC 90 70
 PP 150 105
PAN 120 98
There are two methods to estimate orientation degree:

 Gauge tensile strength of PET slice cut from bottles to estimate its orientation degree. In terms of theory tensile strength after orienting equals its
tensile strength before orienting multiplied corresponding draw ratio approximately. If gauged value is 14MPa less than calculated value, it means
orientation not enough.
 There is another quick and simple method. Cut the bottle and tear it in axes and radial by hand. It means orientation not enough when the bottle be
torn smoothly. On the contrary it means good orientation when the bottle is not easy to be torn.

Thickness of carbonated drink bottles is required to be 0.45~ 0.55mm. But for stretched and blown bottles 0.25~0.38mm will be okay because orientation will
improve products' quality.

Autoloader
H.S.Code: 8477800000

Autoloader is used for loading plastic resin to hopper dryer or plastic injection molding machine automatically based on principle of vacuum .

Feature

model SAL-300C, SAL-300CE

 High speed rectifier motor (PANASONIC/Japan);

 Compact structure, high suction force, suitable for loading virgin resin;
 Easy operation and maintenance;
 Stainless steel hopper with automatic resin-lack alarm;
 Motor protection device;
 Can load resin much more quickly and precisely is equipped with sensor (electric eye, model SAL-300CE).

model SAL-800G, SAL-800G2, SAL-800GE

 Separated design;
 3-phase low-noise blower and filter device suitable for
loading recycled plastic;
 Micro-computer control;
 Stainless steel hopper with resin-lack alarm;
 Motor overload protection;
 Manual and automatic dust clean;
 If equipped with sensor (electric eye, model SAL-800GE),
can be installed on material inlet of injection machine directly.

Specification
 SAL-
Model SAL-300C SAL-300CE SAL-800G SAL-800GE
800G2
Motor Type Carbon Brush Induction
2HP,3-
Motor Spec. 1KW, 1-Phase 1HP,3-Phase 1HP,3-Phase
Phase
Capacity (Kg/h) 300 300 300 550
Max. Static Air Pressure (mmHg) 1300 1440 1440 1800
Hopper Vol. (L) 6 6 6 10
Suction Tube Inner Dia. ø38 mm ø38mm ø38mm ø38mm
Host Dim. (cm) 54x41x36 59x41x36 66x42x37 66x42x37 66x42x37
Hopper Dim. (cm) - - 43x36x26 51x36x26 49x44x31
Host Wt (Kg) 11 10 45 45 55
Hopper Wt (Kg) - - 6 6 7

Hopper Dryer, Dry Plastic Granules’

H.S.Code: 8421199090

The SHD series of hopper dryers (hot air) are the most effective way of drying plastic materials. Drying
directly at the machine throat eliminates the possibility of contamination or re-absorption of moisture
when transporting from a central drying position to the machine hopper. All models offer rapid heating,
24-hour timer; 7-day timer and microprocessor controller which contains P.I.D. temperature control,
digital setting, display of drying temperature, 99-hour timer for auto start-up and fault display
functions for option.

Feature
  The greatest performance hot air distributing device to dry plastic materials at even temperature,
enhance drying efficiency;
 Special designed curved heating pipe to avoid plastic resin piled up at heating elements area,
which causes resin burning;
 Smooth pipe to avoid plastic dust;
 Internal parts are made of stainless steel;
 Hinged construction between hopper body and hopper seat make it easy to clean to change resin;
 Electric temperature controller;
 Two overheat protection devices;
 Over-heated protection device and fuse to reduce accident caused by operation of mechanical
breakdown;
 All models offer the timer, microprocessor and insulated tank for option;
 The P.I.D. temperature controller and LED display; (for model SHD-xxxDT only.)
 0~99-hour timer for start-up; (for model SHD-xxxDT only.)
 Cyclical off and on drying function for energy-saving. (for model SHD-xxxDT only.)

Technical Specification for Hopper Dryer

Model SHD- 50T 100T 150T 200T 300T 400T 600T 1000T

Capacity (Kg) 50 100 150 200 300 400 600 1000

Heater Power (KW) 4.2 6.0 6.0 12.0 12.0 18.0 21.0 30.0

Blower Power (W) 200 250 250 400 400 400 960 960

Suitable IMM(Oz) 5-8 10-20 15-20 20-30 20-30 30 30-50 50+

86x 100x 100x 120x 120x 136x 136x 136x

Dimension
57x 70x 70x 86x 86x 95x 95x 102x
(LxWxH, cm)
100 115 130 162 166 170 208 280

Weight (Kg) 50 95 115 150 175 225 250 300

Power Supply 1Ф 3Ф 3Ф 3Ф 3Ф 3Ф 3Ф 3Ф

Optional Accessories for Hopper Dryer

Magnetic Plinth Application Model Suitable Hopper Dryer

To avoid iron dropping into the MB-50 SHD-50 and below

barrel of injection machine. MB-100 SHD-100
 MB-200 SHD-200

MB-400 SHD-400 and above

Hopper Magnet Application Model Suitable Hopper Dryer

MR5 SHD-12

MR7 SHD-25, SHD-50

To avoid iron dropping into the MR9 SHD-100

barrel of injection machine. MR11 SHD-200

MR13 SHD-400

MR15 SHD-600

Frame A Application Model Suitable Hopper Dryer

AF-12 SHD-12

AF-25 SHD-25

To overcome insufficient height of AF-50 SHD-50

plant. AF-100 SHD-100

AF-200 SHD-200

AF-400 SHD-400~600

Frame L Application Model Suitable Hopper Dryer

Use with hopper dryer and LF1 SHD-100 and below

autoloader together and create a
LF2 SHD-200
neat and clean molding
 environment by placing them away
from injection machine.

LF3 SHD-400~600

Vent Filter Application Model Suitable Hopper Dryer

ADC1 SHD-12

To avoid dust out from the vent of ADC2 SHD-25~100

hopper dryer to keep a clean
environment of plant. The effect for
filtering dusts is up to 80%. ADC3 SHD-200~400

Vent Cyclone Application Model Suitable Hopper Dryer

HCF1 SHD-12

To avoid dust out from the vent of HCF2 SHD-25~100

hopper dryer to keep a clean
environment of plant. The effect for
filtering dusts is up to 100%. HCF3 SHD-200~400

Suction Box Application Model SB

Diameter: 1.5", 2", 2.5";

Use with frame-type hopper dryer Number: 1, 2, 3, 4pcs;

for adapting autoloader and easy
unload. Type: S -- Standard
F -- Air Inlet Filter
R -- Insulated Circulation.
 Throttle Valve: V52 -- for SHD-50 and below
V90 -- for SHD-100~200
V52 -- for SHD-400 and above
Dehumidifier

H.S.Code: 8419399090

The hygroscopic plastics materials such as Nylon, PC, PET and etc. can not be dried effectively by
conventional hot air dryers, because hot air dryers are dependent on ambient conditions and are
relatively inefficient in reducing moisture contents.
These materials demand a steady low dew-point dry air (under -320C) and constant drying
temperature which guarantee a residual moisture content of 0.02% or less.

Once this is achieved, these engineering plastics can exhibit their optimum physical performance and
surface finish. Efficient desiccant dryers can also help the mould avoid avoid difficulties such as
material shrinkage, splash and sink-marks because these dryers operate in a closed loop system dew-
point of the dried air is up to -500C which accelerates the moisture transfer from the plastic granules to
the dry air.

SD Series -- Dew point up to -400C)

Design Feature

 Automatic regeneration cycle, easy to operate.

 Dried air has a dew point of up to -400C.
 A single dehumidifier is installed with a single hopper dryer, easy to install and maintain.
 Small in size to save to more space.
 Dual desiccant towers provide effective dryness.
 Dew point monitor is optional.
 The floor-mounted type of MD Dryer contains the dehumidifier, drying hopper and two loader. It feature in compact size,
mobile, easy to maintenance, and easy to clean out.
 MD dryers is equipped with Dry Air conveying system.

Specification
Dimension Weight
Model Blower (KW) Regenerative Blower (KW) Dry Air Flow (m3/h) Regenerative Heater (KW) Pipe
(cm) (kg)
SD-80 0.75 ---- 90 3 48.5×85×147 126 2"
SD-120 0.75 0.37 120 3.5 60×113×165 260 2"
 SD-200 1.9 0.75 200 4.5 75×134×165 350 2.5"
SD-300 2.6 0.75 300 4.5 75×134×165 410 2.5"
SD-400 4.0 0.75 400 7.5 100×158×192 600 3"
SD-500 5.6 1.9 500 7.5 100×158×192 680 4"
SD-700 3.7* 1.9 700 10 125×170×215 850 4"
SD-1000 5.5* 2.6 1000 15 125×170×215 1100 5"
SD-1500 7.5* 1.5* 1500 30 150×185×230 1300 6"
SD-2500 11* 2.2* 2500 45 195×200×250 1500 8"
Remark:

 With independent drying hopper;

 Based on relative humidity 65% and ambient temperature 200C, moisture content after drying can be 0.02% or less.
 Where marked with "*" means high efficient turbo runner blower.

SD-H Series -- Honeycle Type (Dew point up to -500C)

The molecular sieve and silica gel are strongly bonded to ceramic fibres inside the rotor does not produce any crystallization
therefore, the rotor does not produce any powder and offers an extremely long service life. Moist air passes through numerous
small holes in the rotor (desiccant) winch efficiently absorbs the moisture therefore, the air departing from the rotor is thoroughly
dehumidified and produces extremely low dew-point dry air. Regeneration is operated under the same principle but in reverse
direction through the rotor (desiccant).

Design Feature

 Accurate P.I.D. Temp controller provides digital setting and display of regeneration temperature.
 24-hr timer for auto start-up operation and operation fault diagnosis automatic.
 After cooler fitted standard.
 Adjustable rotation speed of the desiccant rotor.
 Mot overload and phase reversal protection.
 Display of return air temperature.
 Dried air has a dew-point of down to -500C.
 Electrical circuit built to comply with CE Safety Requirements.

Specification
Dimension Weight
Model Blower (KW) Regenerative Blower (KW) Dry Air Flow (m3/h) Regenerative Heater (KW) Pipe
(cm) (kg)
SD-80H 0.4 0.2 80 3.5 75x48x125 120 2"
SD-120H 0.75 0.2 120 3.5 75x48x125 120 2"
SD-200H 1.9 0.4 200 5.4 100x60x168 215 2~2.5"
SD-300H 2.6 0.75 300 7.2 100x60x168 225 3"
SD-400H 1.5* 0.75 400 7.2 138x80x179 240 3"
SD-500H 2.2* 1.9 500 10 138x80x179 280 4"
SD-700H 3.7* 1.9 700 10 138x80x179 300 4"
SD-1000H 5.5* 2.6 1000 15 145x90x199 400 5"
 SD-1500H 7.5* 1.5* 1500 30 150x120x220 510 6"
SD-2500H 11* 2.2* 2500 45 150x135x240 630 8"

Why use Dehumidifier?

Low Water Content

The Relation between

PET's Strength and its
Water Content

For PET, when its water content is over 0.02%, its shock resistance,
elongation performance and tensile strength reduce too much.

PET Preform Injection Mould:

H.S.Code: 8480.7100.90

Molding system plays an important role in food & beverage packaging industry.

Kenplas adopts latest engineering innovation, metalworking

technologies, and mold making know-how to design, manufacture
and test PET preform molds. Kenplas' PET preform mold assures the
customer to produce high-quality PET preforms at high productivity,
but with most economical investment, shortest start-up time and
lowest maintenance cost.

With Kenplas' PET preform mold, medium and small size company
can produce PET preforms by themselves and also satisfy the fresh
brood's production requirement in PET field.

We are enjoying a good reputation on manufacturing close tolerance molds manufactured to rigid customer
specifications.

PET Preform Injection Molding (Size: 1.45Mb, Duration 0'36")

Setup of PET Preform Injection Mold (Size 11.8Mb, Duration: 5'06")

Mold Quality

 Excellent mold steel, STAVAX S136(ASSAB/Sweden) steel or equivalent for mold

core/cavity.
 Chrome-free.
 Coil Heaters, HotSet/Germany;
 Hard mold cavity/core, HRC48-50 as per international standard.
 Long service life, over 2.5 million shots.
 Inter-changeable mold components.
 Balanced multi-Layer hot runner.

PET Preform Qaulity

 Gate-free preform with superior gate quality.

 Low I.V. (intrinsic viscosity loss) loss.
 Low preform eccentricity, no more than 0.1mm.
 Excellent perpendicularity.
 Low weight variation between cavities, less than +/-0.2g.
 Low Acetaldehyde AA level.
 Low preform temperature at exit to avoid preform scratches.

Developing the Mold

 Professional PET Preform Design
>> Make Imagination into Reality
Based on the years' experience and integration with most advanced
mold technology on the world, Kenplas can design preform with both
standard and non-standard neck/shape/volume for water bottle, CSD
bottle and oil bottle with perfect bottle blowing performance as per
customer's bottle requirement.

 Long Service Life

>> Over 2.5 Million Shots
Kenplas' PET Preform Injection Mold enjoys a service life over 2.5
million shots, based on scores years' design/manufacture experience,
mold making know-how, adoption of CNC machining center, high-precision EDM shaping machine and high
precision Jig Boring machine.

o Steel Material and Machining Tools -- Precision

High quality steel like special Anti-rust Mold Steel and Alloy Steel is used to build mold's different parts.
High original hardness and nice machining performance is above steel's mutual features.

o Heat Treatment for Mold Building -- Strong

Kenplas does twin heating treatment for mold's inner parts to enhance their strength and prolong their
using life. After Treatment, the mold core's surface hardness can reach HRC 58~60 degree.
After heat treatment, hard chrome plating will be adopted on Kenplas Preform Injection Mold's inner
part. On normal condition, Kenplas Preform Injection Mold can go on 2.5 millions times of injecting
production cycle at least.

 Gate-Free Preform
>> Labor-Saving

o Valve-Gate Sealing System -- Gate-free Preform

Kenplas Preform Injection Mold adopts Pneumatic Valve-Gate Sealing System
to produce gate-free PET preform, which can save much labor and material
cost, also reduce the mold's wear & tear extent for customer.

o Hot Runner System

Kenplas Preform Injection Mold adopts specially designed Pin-Valve type Hot
Runner System to achieve ideal and prompt heating effect for preform
production. Moreover, such hot runner system reduces mold's each part's
wear & tear and maintenance cost, and also saves 10~15%'s electricity.
 o Heating System -- Quick Response but Energy-saving
Kenplas Preform Injection Mold adopts double Heating system to ensure perfect heating effect and
reliable quality control. The Heater Unit is used to heat the hot runner plate with long service life and
powerful heating capacity. The Heating Ring System is used to ensure the mold nozzle's constant
heating temperature.

o Hydraulic Ejecting System -- Quiet, Long Service Life

Kenplas Preform Injection Mold adopts hydraulic ejecting mode to replace the mechanical type Hook
Doffing System for smooth preform doffing process. The preform-doffing success ratio has achieved
firm insurance and the whole preform ejecting process will become much quieter.

 Cooling System
>> Short Cycle Time & Perfect Preform Quality
In each inner mold part, there is well-designed cooling system with perfect cooling effect and abundant
strength.

 Low Preform Eccentricity

>> Leave Preform Eccentricity Away

o Self-lock System
Long bi-awls (double-taper) fixed orientation advanced techniques has been adopted on Kenplas
Preform Injection Mold to reduce the preform eccentricity problem caused by outside reasons.

o Patent Designed Rectifying System for Preform's Eccentricity -- Double Insurance on Preform Eccentricity
Patent Designed Rectifying Device has been equipped on Kenplas Preform
Injection Mold to remove preform eccentricity possibly occurs during preform
production. After rectified, the preform wall's eccentricity can be adjusted
below 0.05mm again.

 After-Sale Service
>> Have a good sleep
Before delivery, each mold will bear strict test. Detailed parameters will be recorded
with their own sole serial number. And full set of enough spare part will be equipped
with mold to ensure mold's normal working. Moreover, during mold's using period,
Kenplas ensures abundant normal spare part supply for any requirement. Kenplas
helps you solve all the problems happened during production.

Mold Cavity Layout & Dimension

Cavity Number 1 2 4 8 12 16 24 32
Cavity Layout (Col*Row) 1*1 1*2 2*2 2*4 2*6 2*8 4*6 4*8
Mold Height (mm) 200 350 350 500 640 790 740 860
Mold Width (mm) 200 200 270 300 350 380 600 670
19g,90mm long 295 305 315 325 360 370 590 590
Mold 25g,100mm long 305 315 325 335 370 380 600 600
Thickness 28g,110mm long 335 345 355 365 405 415 635 635
(mm) 38g,135mm long 380 390 400 410 450 460 680 680
42g,145mm long 400 410 420 430 470 480 700 700

Production Analysis: 24g Preform for 500ml Water Bottle with PCO Neck

Cavity Number 4 8 12 16 24
Material Type PET resin with viscosity around 0.78~0.80
Cycle Time (sec.) 15 18 20 22 24
Output (pcs/hour) 960 1600 2160 2650 3600
Shift Time Standard 8 hours
Output (pcs/shift) 7680 12800 17280 21200 28800
Material Supply (kgs/shift) 190 310 420 510 700

Production Analysis: 32g Preform for 1000ml Water Bottle with PCO Neck

Cavity Number 4 8 12 16 24
Material Type PET resin with viscosity around 0.78~0.80
Cycle Time (sec.) 16 20 22 24 28
Output (pcs/hour) 900 1440 1960 2400 3085
Shift Time standard 8 hours
Output (pcs/shift) 7200 11520 15680 19200 26480
Material Supply (kgs/shift) 230 370 510 620 800

Production Analysis: 42g Preform for 1500ml Water Bottle with PCO Neck

Cavity Number 4 8 12 16 24
Material Type PET resin with viscosity around 0.78~0.80
Cycle Time (sec.) 18 22 25 28 30
Output (pcs/hour) 800 1310 1728 2060 2880
Shift Time standard 8 hours
 Output (pcs/shift) 6400 10480 13824 16480 23040
Material Supply (kgs/shift) 270 450 590 700 980

Pricing
Neck Size
<=Dia.32 mm
 Dia.38 mm Weight<40g
Weight<40g
Dia.45mm
Weight>=80g
Dia.60mm Weight<50g
Dia.70mm Weight<60g
Dia.83mm Weight<75g
Dia.100~110mm
Dia.130mm
Dia.180mm

Extra Puncher
Extra Puncher with Holding Plate
Spare List for PET Preform Mold (Gate-Free)
Name <=6 Cavity >=8 Cavity
Mold Temperature Controller 1 Set 1 Set
Temperature Meter 1 Pc 25% of Whole Mold
Mold Core/Cavity (None) 1 Pair
Neck Split 1 Pair 25% of Whole Mold
Nozzle Heater (with thermocouple if used) 25% of Whole Mold 25% of Whole Mold
Insulation Cap for Nozzle 25% of Whole Mold 25% of Whole Mold
Sealing Rings for Cylinder 100% of Whole Mold 100% of Whole Mold
Tabular Heater 1 Pc 50% of Whole Mold
Plastic Injection Molding Machine HSJ Series
i-Master HSJ series plastic injection molding machine can deal with general purpose thermoplastics such as PolyEthylene(PE),
PolyProplene(PP), PolyVinyl Chloride(PVC), PolyStyrene(PS), Nylon, PolyCarbonate(PC), Acrylonitrile Butadiene Styrene
Copolymer(ABS), etc.
Specially designed HSJ series PET injection molding machine meets the processing requirements of PET material at most.
Models Available HSJ Series KPET Series HIPET Series
  Model HSJ-90.  KPET8;  HIPET-48;
 Model HSJ-120.  KPET12;
 Model HSJ-150.  KPET16;
 Model HSJ-180.  KPET24;
 Model HSJ-220.  KPET32.
 Model HSJ-250.
 Model HSJ-300.
 Model HSJ-330.
 Model HSJ-350.
 Model HSJ-400.
 Model HSJ-480.
 Model HSJ-580.
 Model HSJ-650.
 Model HSJ-760.
 Model HSJ-880.
 Model HSJ-1080.
 Model HSJ-1250.
 Model HSJ-1680.
 Model HSJ-2000.
 Model HSJ-2500.

Advantage of HSJ Series

 Robust box style mold platen by direct iron casting;

 Larger mold capacity (opening stroke, mold thickness and space between tie-bars);
 (Optional) Differential injection device and clamping unit (higher speed but lower pressure);
 Self-lubricating bushes used in guide rods and tie-bars for smooth running and eliminating the need of external
lubrication of machine surfaces and plastic goods.

Typical Parts
Safety Device
 Hydraulic Safety Electrical Safety Device
Mechanical Safety Device
(by Yuken/Taiwan Valve) by Limit Switches (OMRON/Japan)
Controller & Electrical

 AC Contactor -- Schneider/China;
 Limit Switch -- Panasonic NAIS;
 Proximity Switch -- DEPU/Germany;
 Band Heater -- Standard/HongKong.

Panel of A63 Controller Board & Wiring of A63 Controller

(by Techmation/Taiwan) LCD Display (6") (by Techmation/Taiwan)
Position Transducer (Linear Potentiometer), made by DEPU/Germany

for Clamping Unit for Injection Unit for Ejector

Valve, Hydraulic Pump & Hydraulic Motor

 Valve Board for Clamping Unit
Valve Board for Injection Unit
(Directional Valve -- VICKERS/USA; Hydraulic Pump Hydraulic Motor
(Proportional Valves --
Back Pressure Valve, Check Valve: (VICKERS/USA) (Intermot/China)
HNC/Taiwan)
LINDE/Taiwan)
Others

 Sealing Ring, Composed Sealing Ring -- Japan.

Enhanced Cooling Blower for

Hydraulic Hose(MANULI/China) for Easy Mold
Water Distributor Purge Guard to Protect Operator's
Electrical Cabinet to Stand High
Protected by Stainless Spring Mounting Safety
Temperature
Design Feature
Injection Unit

 Balanced double cylinder injection system with compact structure;

 Optional A, B, C screw & barrel for process of different material;
 Big L/D ratio and precision-boned heating barrel ensure increased plasticizing efficiency and ease of barrel
flushing;
  Screw made by high precision CNC thread grinder to achieve strong plasticizing capacity and homogeneous
mixing;
 Nitrided screw and heating barrel ensure optimum performance and lasting service life;
 Electro-hydraulic proportional valve features easy adjusted pressure and flow increase reliability and sensitivity;
 Easy adjustable multi-step pressure, speed of INJECT & HOLD-PRESSURE;
 Screw directly driven by a high torque hydraulic motor with 99-step speed and 140-step pressure, thus suitable
for wide range of material;
 Linear potentiometer for screw stroke control;
 P.I.D. temperature control;
 SUCK-BACK function;
 Pressure gauge indicates injection pressure;
 Screw and heating barrel made of high-quality 38CrMnAlA assure long service life.

Clamping Unit

 International standard toggle mechanism;

 Platen and toggle in accuracy machined by CNC machine center;
 Large open stroke, efficient and reliable movement;
 High quality tie-bars using 40Cr steel;
 Automatic mold-height adjustment by hydraulic motor through a planetary gears system
ensures fast and constant settings;
 Multi-eject function with adjustable pressure, speed, position and delay time;
 Low pressure MOLD-PROTECT;
 Linear potentiometer for mold clamp position control;
 Three stages of MOLD-OPEN/CLOSE pressure and speed control;
 Whole-covered guide of clamping unit ensures the operator's safety.

Appearance & Foundation

 Level pads for foundation are easy for operators to move, install and level the machine;
 Oil filters, oil level and oil alarm system in the oil tank;
 Whole-covered safety guide is artistic and strong, movable for maintenance.

Hydraulic & Lubricating System

 Accuracy hydraulic proportional control system;

 Multi-pump system saves energy;
 Efficient and reliable hydraulic circuit;
 Oil temperature alarm device & emergency stop device;
  Core pulling;
 Automatic lubricating system with leakage and low level alarm.

Computer Controller model A63

 A63 computer controller, which adopts the most advanced control

technology and design, is reliable and precise microprocessor based
controller especially for plastic injection molding machine;
 Basic circuit design includes standard photo coupling wiring circuit and high
noise reduction characteristic;
 Dust-proof embrace operation key panel switch box;
 Suitable for various hydraulic proportional system;
 There are several engineering data stored in internal memory, which can be
initially set by operator at machine setup time, ensure operation in optimum
condition;
 Self-test function for maintenance;
 Manual, semi-auto, auto mode available.

Features of A63 Controller

Type PLC (e.g.) A63 Controller

Computer Controller FX0N-60MR (MITSUBISHI/Japan) A63 (Techmation/Taiwan)
Position Control Proximity switch, Limit switch Potentiometer, Proximity switch, Limit switch
Potentiometer No Yes(3 pcs)
Mold Data Memory No Yes (20 molds)
Data Input Dial switch Keyboard
Temperature Control Temperature controller Computer controller
Time Control Time relay Computer controller
Internal Program & Data Unmodifiable Modifiable
Screw Protection No Yes
Data Display LED LCD
Date & Time No Yes
Auto Heating No Yes (24-hour)
Alarm Flash & sound Flash, sound & data indication
Safety Device Electric & Mechanical Electric & Mechanical
 Air Eject No Yes (optional)
Core Pulling No Double core pulling (optional)

PET Bottle/Jar Stretch Blow Molding

PET Bottle Processing:

Heat and soften PET preform -- heater;

Blow high pressure air into preform and form bottle -- stretch blow
molding machine, blow mold, air compressor, air purifier.

Stretching blow molding is also called biaxial orientation blow molding. It

is a kind of package container producing method stretching preform in
axes by mechanical device and in radial by compressed air ( air should be cleaned
by air purifier if necessary) when material is under high elasticity condition. This is
widely used for PET, PE, PVC and etc.

Orientation can improve product's mechanical property, solvent resistance, transparency and anti-permeability.
Polymer molecule is unbalanced long-chain structure. Orientation happens when stretching. Orientation means
molecule arrange along stretching direction parallelly.

Stretching blow molding brings biaxial orientation effect to the products. To cool products quickly means high
orientation degree.

The glass transition temperature of PET is 820C, and its best orientation temperature is 1050C.
Solution for PET Bottle/Jar Blow Molding
PET Stretch Blow Molding
PET stretch blow molding machine is a kind of container making method that stretches PET preform in axes by
mechanical device and in radial by compressed air when PET preform is under high elasticity condition.

Orientation can improve products' mechanical property, solvent resistance, transparency and antipermeability. Polymer
molecule is long-chain structure which is unbalanced. Orientation happens when stretching. Orientation means
molecule chains arrange along stretching direction parallel.

Stretching blow moulding brings biaxial orientation effect to the products. To cool products quickly means high
orientation degree. So to reach satisfactory orientation effect, we can raise stretch speed, increase polymer's molecular
weight or lower stretching temperature.

In orientation molecular chain can move freely along pulling force temperatures for four different materials.

Best Orientation Glass Transition

Material
Temperature (0C) Temperature (0C)
PET 105 82
PVC 90 70
PP 150 105
PAN 120 98

There are two methods to estimate orientation degree:

 Gauge tensile strength of PET slice cut from bottles to estimate its orientation degree. In terms of theory tensile
strength after orienting equals its tensile strength before orienting multiplied corresponding draw ratio
approximately. If gauged value is 14MPa less than calculated value, it means orientation not enough.
 There is another quick and simple method. Cut the bottle and tear it in axes and radial by hand. It means
orientation not enough when the bottle be torn smoothly. On the contrary it means good orientation when the
bottle is not easy to be torn.

Thickness of carbonated drink bottles is required to be 0.45~ 0.55mm. But for stretched and blown bottles
0.25~0.38mm will be okay because orientation will improve products' quality.
Kiram Services

description

Cité 1200 logts, Résidence El-Khayam, Bloc A app. N°5, Bab-Ezzouar 16110, Alger Algérie

Tél. (+213) 21 24 03 05 / (+213) 21 24 08 80

Fax : (+213) 21 24 03 04 www.kiram-services.com