KhS corpoplaStpackaging SolutionS and Stretch bloW Molding – SySteMS for plaStic bottleS

02 03

4-5 Bottledesign

6-7 Bottledevelopment

8-9 LightWeighting

10-11 ConceptofBlomaxSeriesIII

12-15 HighlightsofBlomaxSeriesIII

16-17 Energyandcostsavings

Contents

18-19 Hotfill

20-21 PreferentialHeating

22-25 Service

Asatechnologypartnerofthebeverage

industrywith30yearsofexperience,

weknowthateachdecisionfora

stretchblowmoldingmachinestarts

withthequestionabouttheproductto

befilledandthecorrectpackaging.

Thisbrochuredoesnotthereforestart

withthefeaturesandbenefitsofour

BlomaxSeriesIIImachinetypesbut

withthewidevarietyoffilledproducts

andthewiderangeofPETbottles

producedwithourmachines.

Wewouldliketodemonstratehowand

atwhichstagewedrawonourcom-

prehensiveknow-howandtheservices

ofourtechnologycenteronthematter

of«Bottles&Shapes™».Thisreflects

howwedevelop«your»perfectbottle

fortherelevantproducttobefilled.

Naturally,allsignificantdetailsregard-

ingourstate-of-the-artBlomaxSeriesIII

stretchblowmoldingmachinesarealso

included.Afterall,wealreadyconsider

thebestpossiblefurtherprocessing

methodsduringthedevelopmentphase

–forexample,thedownstreamfilling

lines.Implementationofourknow-

howwithregardtoPETprocess,bottle

designandconstructionalsoplaya

decisiverolefortheallimportant

result,thatyourindividualpackaging

solutionwillmeetallyourrequirements.

Blomax Series III Stretch blow

molding machines – a perfect solution

for all filled products

04 05

Hotfill

PrecisionPlasticsLtd.ThailandIVYTeaRoundRibbed0.5l27gBlomax16HRSeriesIII

Juice

Eckes-GraniniGmbH&Co.KGGermanyGraniniOrangeOrangeJuiceRoundChampagne1l39gBlomax18SeriesIII

CSD

Customer: BritvicSoftDrinksLtd.Country: UKProduct: TangoContent: AppleflavouredCSDShape: RoundBase: PetaloidVolume: 0.5lPreformweight: 28gSBM: Blomax12SeriesIII

Water

OAOKCRussiaIcevaPureStillWaterNotroundRibbed0.5l23gBlomax6SeriesIII

Tea/Energy/PLA

PLABrandsofAmerica,Inc.USABIOTASpringWaterRoundRibbed12oz/0.355l20.5gPolylactid(Corn)Blomax10SeriesIII

Beer

Customer: MoscowEFESBreweryZ.A.O.Country: RussiaProduct: SokolContent: BeerShape: RoundBase: PetaloidVolume: 1lPreformWeight: 42gSBM: Blomax8SeriesIII

Food/Non-Beverage

WeenerPlastikGmbH&Co.KGGermanyNiveaShowerCreamOvalInverted0.2l21.2gBlomax4PHSeriesIII

Milk

NÖMAGAustriaTrinkSnackYogurtCerealDrinkRoundChampagne0.5l26gBlomax12SeriesIII

EachfilledproductrequiresanappropriatebottleandthePETbottlecontributestotheimageofyourproduct.Atthesametime,thebottleshouldhavepropertiesthatenableitto«stayinshape»duringhigh-performanceproduction.Tomakesurethathappens,bottlesandmoldconstructionaswellastheentireproductionprocess,mustbeoptimallycoordinated.Ourcustomersbegintobenefitatthispointfromtheuniquetotalknow-howofKHSCorpoplast.

So,letyourimaginationreinfree.Wewillmakeyourbottledesignfitforproductionwhilealwaystakingintoaccounttechnicalandeconomicalfeasibility.

ThousandsofPETbottledesignshavealreadybeendevelopedatourHamburgtechnologycenter.Wecanthereforeassureyouwithconfidencethatwewillbeyourcompetentpartnertoimplementyourideasandwishes.

Ourprocedureisasfollows:Withour3DCADsystem,wewillfirstdemonstratehowyourideacanbeturnedintoyourfutureproduct.Allconceivableinfluencesonthebottlearedetermined,analysedandevaluatedatthispointinordertoachieveoptimalresults.

Wethencreateyourinitialprototypeonour3D«printer»withinjustafewhours.

Inthenextstep,thefirstsamplebottleismanufacturedusingapilotblowmold.Thisisthentestedunderrealconditionsinourstate-of-the-artlaboratory,e.g.regardingbreakingandstackingstrength,wallthickness,burstingpressureandstresscracking.

Atthisstagewecanmodifyandoptimiseuntilallrequiredbottlespropertiesaremet.Thepathisthencleartomanufacturethemolds–aprerequisitefortrouble-freemassproductionofyourPETbottleswiththehighestguaranteedquality.

Bottles & Shapes™: The contents determine the bottle

06 07

Top Load

Tolerances

Thermal Stability

Shelf Life

Creep

Micro-Biology

Stability of Grip Area

Burst Pressure

Impact Resistance

Stress Cracking

Stiffness of Base

Workgenerallycommenceswiththepackagingdesignproposal–animportantdetailofyourmarketingconcept.ThefirsthurdletobenegotiatedisthatnoteverybottleshapecanbemanufacturedusingPETwithstretchblowtechnology.Butjustabout!

TheKHSCorpoplastCADarchiveincludesapprox.12,000bottledesigns–asignificantbenefitforourcustomers.Thankstoour30yearsofexperience,wecanadviseyoupreciselyanddevelopablowablebottlewhichcanbepro-ducedexactlytoyourrequirements.

Throughtheprocessofevaluatingtheproducttobefilled,thePETbottlesizeandshape,youwillgettoknowourtechnologycenterandtheKHSCorpoplastcorecompe-tency–andyouwillcertainlyappreciateourdefinitionofthesimpleconcept«Bottles&Shapes™”.Becausenowwewillstarttodeveloptheappropriatebottlewithyou–withoptimalpropertiesandthelowestpossiblemanufacturingcosts.Guaranteed!

Bottles & Shapes™: From design to the perfect bottle

Fourareasdeterminebottledevelopment:• Design• Weight• Process• Laboratory/tests

Thedesignincludes:• Developmentandconstructionwithstate-of-the-art CADCATIAV5programs• 3Dprototypingwithinhoursonour3Dprinter• ProblemanalysisandsolutionsbasedonFiniteElement Analysis(FEA)• Samplebottles

Theweightisbasedon:• Preformdesigndependentonthestretchingratio• LightWeighting,basedontechnicalandeconomical feasibility

Factorsinfluencingtheprocess:• Highspeeds• Lowblowingpressure• Lowheatenergy• AlternativematerialssuchasPLA(polylactid)or PP(polypropylenes)

Criteriaforlaboratory/tests:11mainpoints–asdemonstratedonthesamplebottleshownhere.

Bottle construction 3D printer Top load tester

11 criteria for Laboratory/tests:

08

Theprincipleissimple:Weightreductioninbottleproductionleadstolowerblowingpressure,lessPETmaterialandreducedheatinginput.

Professionalimplementation:ToreducetheweightofyourPETbottle,yourequireacompetentpartnerwithcomprehensiveknow-howinPETprocessing.Wehavecompleteknow-howinanalmostuniquecombination:Intensiveresearchanddeve-lopmentinourtechnologycenterandclosecooperationwithMoldtecforthemanufactureofstretchblowmoldsandinjectionmoldingtools.

Becausewehave30yearsofexperiencein

•Packagingtechnology•Processknow-how•Preformdesign•Bottledesign•Stretchblowmoldingtechnology

wecanguaranteethatLightWeightPETbottlesproducedonBlomaxmachinesalwaysmeetthedefinedspecifications.

AndLightWeightingcounts:WithaBlomax10SeriesIIIapprox.78,000,000PETbott-lescanbeproducedannually.Ifyousavejust1gramofPETmaterial(1kg=EURO1.20)perbottleatthisproduc-tionvolumeyoucansaveuptoEUR93,600!

Pneumatic stretching

Mechanical stretching

Bottles & Shapes™: Light Weighting

Development in Light Weighting

PET quantityin grams

1.5 l CSD: reduced from 44 g to 31 g

0.5 l CSD: reduced from 28 g to 15 g

0.5 l water: reduced from 18 g to 12 g

Process stability

Base weight

Bottles producedYear 2000 2007

Target weight pneumatic stretching

Target weight mechanical stretching

01

02

03/11

04

05

07

08

09

12

1310

06

10 11

TheBlomaxSeriesIIIcancoveranareaof4to24cavitieswiththeunusuallypracticalmodulesysteminthefollowingsequences:

Room for individual solutionsTheoverallBlomaxSeriesIIIconstructionismodularindesign.Weusestandardisedsubassembliesforthemainmachinemodulessuchasthetransportmodule,linearovenandblowingmodule.Theheaterboxes,heatingtrainandblowmoldingstationsarealsomodular.Thisallowsustoofferyoucost-effectiveflexibilitywhenchoosingyourBlomaxSeriesIII.

Always the right moduleEquipyourBlomaxmachinewithexactlywhatyouneedtomeetcurrentandfuturerequirements.Thisisnopro-blemaseverymodulematcheseachmachine.A«specialdesign»simplyconsistsofadifferentconfigurationofstandardmodules.Yourbenefits:•Nospecialmachineconstruction•Noadditionalcostsfor«specialdesigns»•Shorterdeliverydeadlines

The modular system is economicalAllBlomaxSeriesIIImachinetypeshaveidenticalprocessengineering.Thishasenormousadvantagesforourcustomers.

Maximumflexibility:EachbottleproducedonaBlomaxcanalsoeasilybeproducedonanyotherBlomaxmachinetypewithoutlaboriousprocessadjustments.

Greatfamiliarity:OncetrainedonaBlomaxmachine,operationandmain-tenancepersonnelarefamiliarwithallotherBlomaxmachines.

Simplemaintenance:Therequiredsparepartsstockcanbereducedatourcustomer’splant.Futuremodernisationorupgradepackagesgenerallyfiteachmachinesize.

Rapidsparepartsservice:KHSCorpoplastmanufacturesandassemblesmostmodulesregardlessofmachinesize.Thismeansflexiblereactiontorapiddeliveryrequirements.

Flexibility for individual components as wellThelinearovenisavailableinthreesizesbasedonthenumberofblowstations.Thelengthoftheovencanbealteredwithincertainlimitsbyshiftingthedwellpoint.Inordertomeetvariousheatingperformancerequirements,allthreelinearovenscanbecombinedwithanytrans-portorblowingmechanism.TheBlomax4,6and8haveaone-piecemachineconcept.Thismeansthemachineplatformisdirectlyconnectedtotheheatingmoduleorlinearoven.Anupgradeiseasythankstothemodularconstruction.Ifyouplanfutureexpansionswith

additionalheaterboxes,youshouldorderalargeroven.Theheatingtrainisthenadaptedtotheactualrequiredovenlengthbymountingthecorrespondingamountofmandrelcarriers.Youcanalsoproducebottleswithalar-gerneck(from36to49mmneckdiameter)ifrequiredatalatertime–justselectalargerpitchontheheatingtrain.

Theblowingwheelconsistsofaringtowhichtheblowmoldingstationsarebolted;theringisconnectedtothemachineplatformviaaballbearing.Thisringconstructionisidenticalforeach«machinepair»intheBlomaxSeriesIIIandhasallconnectionpointsforeachtype.ThisnotonlyprovidesflexibilitywhenassemblingthemachinesattheKHSCorpoplastplant,butalsoenablesyoutoexpandyourBlomax4,10,14or18byafurthertwoblowmoldingstations–atyourplantandwithoutdisassemblingthemachine.Unlimited modularityMostmachinesaresuitableforaircargotransportbe-causeoftheirtransfer,heatingandblowmoldingmoduleconstruction.ThemaximumdimensionsofthemoduleshavebeendeliberatelydesigneduptotheBlomax16fortransportina747cargoplane.

Themachineiswiredupwithconnectorsbetweenthemodulesandtheintegratedcontrolcabinet(exceptBlomax4,6and8whicharebasedonaone-piecemachineconcept).

Thisenablessimplere-connectiononsite–agenuine«Plug-and-Play»installationrapidlycompletedincludingcommissioningandstart-up.Themodularconstructionisalsoeconomicalwithregardstomaintenance.Somecomponentscansimplyberemovedfromthemachineforadjustment,maintenanceorrepair.Thechangeovertimesare:•1minforaheaterbox•3minforaturningwheel•30minforacompleteblowmoldingstation

01 Turningwheel

Loadingstation

02 Loadingstation

03 Loadingandunloading

wheel

04TransferstationI

Blomax Series III: The modular machine concept

Blomax 12 Series III

Blomax Series III machine key features(schematic)

05 Linearoven(smallestmachine)

06 Linearoven(largestmachine)

07 TransferstationII

08 Blowingwheel(smallestmachine)

09 Blowingwheel(largestmachine)

10TransferstationIII

11 Loadingandunloading

wheel

12 Bottleturningwheel

13 Electricalcabinet

Baseareaoflargestmachine

Baseareaofsmallestmachine

Transfermodule

Heatingmodule

Blowmoldingmodule

Blomax Series III compact Blomax Series III standard

4,6,8,10 4,6,8

12,14 10,12

16,18 14,16

20,24 18,20

12 13

OurcustomersbenefitfromKHSCorpoplast’sdecadesofPETprocessexperienceandfromtheconstructionanddesignofstretchblowmoldingmachinesthatmeettherequirementsforthecost-effective,reliableandpreciseproductionofhigh-techPETbottleswithtopoutputandmachineavailability.

Wecallthis«ValueAddedBottleBlowing»–ahighdemandwhichismetbythekeyfeaturesofourBlomaxSeriesIIImachines.

1. Transport mandrels MandrelsandtheircirculationthroughthemachinearestandardcomponentsintheBlomaxSeriesIII.Throughcontinuousdevelopmentofthisreliableandhighlyefficientcomponentwithregardtodimensionalaccuracyandrepeatabilityduringprocess,thetransportmandrelprinciplesupportsaminimumprocesstimeparticularlyforhighspeedproduction.Impuritiesinpreformsandbottlesareavoidedbytheneck-downprinciple.

Blomax Series III: Highlights

2. Low energy consumptionThelowheatingandcompressedairconsumptionintheBlomaxmachinesisatradition–thelowestenergyconsumptioninthisindustry.

a)Heating•Mandrelpitchonly38mm•Highheatpenetrationofpreforms•Optimaluseofheatingenergy•Flexibilityofheatingmodules•Corecooling

b)Compressedair•Lowestdeadairvolumethroughvalveblockdirectly installedatthestation•AirrecyclingfromP2toP1directlyintothe productionprocesswithoutcompromisingtheprocess•Reducedblowingpressure<30barispossible

3. Stretching systemThemechanical,cam-controlledstretchingenableshighprecisionandrepeatabilitycomparedtopneumaticstretch-ing.Thisisasignificantprerequisiteformaterialsavingsinlightweightingandcostreductioninairconsumption.Changeovertimescanbereducedby25percentbecausethestretchingrodisonlyadjustedduringproductchangesandnolongerexchanged.

4. Blow molding stationBlowmoldingstationsarealsoamodularelementintheBlomaxSeriesIIImachineswiththeirmoldholders,outerandinnershells.Theyareavailableforallmachinesizesandarethereforeexchangeableandcost-effective.Thecompactnewgenerationblowmoldingstationsoperatewithasupportwheelandcam-controlledopeningandclosingmechanismsforincreasedstabilityandconsistentbottlequalityinhighspeedproduction.Thepre-installedairrecyclingsystemAIRBACKautomaticallysavesupto100percentoftheairrequiredforpre-blowing(recircula-tionfromP2toP1).Thecompactconstructionofthevalveblockdirectlyattheblowmoldingstationreducesthedeadairvolumeandalsosavesairenergycosts.

Blow molding stationTransport mandrel

Heater boxes

Cam-controlled stretching

14

1

2 2

3

5. Quality assurance systemsWeoffernumerousqualitycontrolsformaintainingma-chineavailabilityatthehighestlevel.

a)PreformtestingOnlyimpeccablepreformsguaranteepreciseheatingandstretchblowmoldingprocesses.Weprovidetestingdevicesinstalledattheperforminfeedortransferstation1tosortoutdamagedperforms.Thesystemsarevideo-supportedandeliminatepreformswithirregularnecks.

b)Bottletesting(Offcentremeasuring)Testingsystemsdetectingnon-axial,irregularbottlesareeitherinstalledupstreamoftheairconveyinglineorattherotatingwheel.Damagedbottlesareeliminated.

c)Bottletesting(wallthicknessmeasuring)Forprocesstestingweofferavideo-supportedinlinetestingsystemformeasuringthewallthicknessesofblownbottles,inparticularafterproductchangeandforLightWeighting.

6. ModificationModificationsduringproductchangesshouldnotinflu-enceprecisionorreliabilityofthemachines.Implemen-tationmustbesimpleandaboveallrapid.Astherapidexchangesystemsarecontinuouslyunderdevelopment,themodificationtimesaresignificantlyreduced.TheKHSCorpoplastSpeed-Locsystemwithitsrapidexchangecomponentsfor•Moldsection•Basemolds•Stretchingrodensurestheshortestpossibleproductchange-over.

Thebasemolds(multi-coupling)andthemoldshellscanbeeasilyremoved,screwsandhoseconnectionsdonothavetobeundone.Thenewgenerationstretchingsystemdoesnotneedanystretchingrodexchanges.Adjustmentduringproductchangeissufficient.TheSpeed-Loccomponentsreducemodificationtimestoaminimum.

Wall thickness measurement

Speed-Loc rapid exchange system

1| Product change: Remove/insert base mold

2| Product change: Remove/insert mold section

3| Undo screws, adjust stretching rod

16 17

140

120

100

80

60

40

20

0

KHS Corpoplast

P1

P1

P2 AR EX

P1

P2

P2 AR EX

P1 P2 AR EX

AR

P1 P2 AR EX P1 P2 AR EX

ThecostsforPETbottleproductionareroughlydividedasfollows:•70percentmaterial(PET)•15percentpreformproduction•15percentbottleproduction

Optimalbottledesignisasignificantprerequisiteforcost-effectiveproduction.ThedecisionforaKHSCorpoplaststretchblowmoldingmachinepaysrightfromthestartofproduction.BlomaxSeriesIIImachinestraditionallyfeaturethelowestenergyconsumptioncomparedtothecompetitors.

Wecandirectlyinfluencethe15percentproductioncosts.Theseconsistof:•Investment•Heatingenergyconsumption•Airconsumption•Reliability

InvestmentOurBlomaxmachinesaredistinguishedbytheirmodu-larconstructionandhighstandardisation.ThetransportmandrelisastandardfeatureinallBlomaxmachines.Theneck-downtransportofthepreformpreventscontaminationinpreformsandbottles.Themandrelcirculationiswear-resistantandsupportsthehighoutputsbyabsolutedimensionalaccuracyandconstant,preciserepeatabilityoftheentireprocess.AdecisivefactorforLightWeighting.

Heating energy consumptionTheverylowmandreldistance(pitch)ofjust38mmenableBlomaxmachinestoachievehighlyefficientheatpenetrationofthepreformsandtopindustrialvaluesinheatingenergyconsumption.Individuallyadjustablehea-tingmodulesandanefficientmandrelcoolingalsoreduceenergyandtimecosts.

Air consumptionTheKHSCorpoplastAIRBACKsystemenableslowestdeadairvolumeandupto100percentrecycledairfromP2forthepre-blowprocessP1.Inaddition,theredu-cedblowingpressureinLightWeightingresultsinverylowcompressedairconsumption.Costsforgeneratingcompressedairrequirementsandairconsumptionarethelowestinthisindustry.

ReliabilityTheavailabilityofKHSCorpoplaststretchblowmoldingmachinesistraditionallyexcellentandabenchmarkforthecompetition.ItisourPETprocessknow-howthatenablesustoofferthebeststretchblowmoldingmachi-neswiththeBlomaxSeriesIII.Inaddition,ourserviceisavailablearoundtheworldsothatwecanrespondtoyourqueriesrapidlyandprovidesupport.

Blomax Series III: Best of its class for production costs

Preform on mandrel circulation

Mandrel

Competitors

Mandrel distance (pitch)

Pitch 38 mm

Energy consumption per kg PET

Percent

Mandrel

stationwithfullyblownbottle

stationinpre-blowphase

AIRPANEL

stationwithfullyblownbottleinAIRBACKphase

stationwithfullyblownbottleinexhaustphase

4-stagecompressor

volumeflowcounter

distributorring

KHSCorpoplastAIRBACK/AIRRECYCLING(blowingcycleofonestation)

18 19

32 26

50

40

30

20

10

0

< 0.60 l < 1.0 l < 1.25 l < 1.50 l < 2.0 l

1,400 1,200 1,200 1,000 950

1,200 1,100 1,000 950 –

1,000 850 750 700 –

950 800 700 600 –

According to application and bottle size

Hotfill,inlinefill(btl./hr)Cylindricalmold,max.temperature88°C,standardneck

Hotfill,inlinefill(btl./hr)Cylindricalmold,max.temperature92°C,crystallisedneck

Hotfill,offlinefill(btl./hr)Cylindricalmold,max.temperature88°C,standardneck

Hotfill,offlinefill(btl./hr)Cylindricalmold,max.temperature90°C,crystallisedneck

HotfillisasuitablealternativetocoldasepticfillingiftemperatureandsensitivityoftheproductduringPETbottlefillingplaysaroleandbarrierrequirementsmustbecompliedwith.TherequirementsforPETbottlefillingwithheattreatedproductsaremainlydependentontheproduct,marketrequirementsandshelflife.

Thedesignelementsandtheprocessparametersmustbeselectedcarefullytooptimisethecost-effectivenessofamachine.

Highest demands for Hotfill processesJuicesandteasarefilledintoPETbottlesatatemperatureof92°C.Ahighcrystallinityisrequiredtopreventmois-tureaffectingthebottlequalityduringtemporarystorage.

AbottleforHotfillnolongerhasauniform,classical«ap-pearance».EvenunusualbottledesignsarepossibleandtheycanhardlybedistinguishedfromtraditionalPETbottles.

Viscousproductsrequireawiderbottleneckandadesignthatenablesbetterabsorptionofthevacuumproducedduringcoolingdownfromthebottlingtemperature(96°C).Thesepropertiescanbeincludedbymeansofspecialsolu-tionsinmachineconstruction.Inordertopasteuriseabottleat75°Cfor30minutes,thebottlemustbetotallystress-freeandgeometricallydesignedtowithstandtheprocess.

Blomax modular construction for optimal resultsBlomaxSeriesIIImachinescaneasilybeadaptedtoHotfillprocessesfromrelaxorstandardblowmoldingprocesses.Maximumoutputisguaranteedforeachprocessthankstothemodularconstructionwithexchangeablecomponents.

InHotfill,thetemporarystoragetimeforabottlebetweenblowmoldingandfillingisadecisivefactorastowhethermaximumoutputforadefinedcontainersizecanbemet.Thereason,thebottleabsorbsmoistureduringstorage,affectingthermalstability.Ifbottlesarefilleddirectlyafterblowmolding,thisso-calledinlineprocessleadstoapro-ductioncapacityof1,400bottlesperhour.Thecapacityforthesamebottlesisreducedto1,000perhouriffilledaftertemporarystorage.

Ourtableoverviewincludesnormalvalues,dependentoncontainersizeandfillingprocess.Pleaserefertotheover-viewonpages26,27and28inthisbrochureformachinespeeddataandotherprocesstypes.

Blomax HR Series III mode of operationThepreformisheatedtomaximumtemperatureandblowninahotblowmold.Thematerialisalignedintheblowmoldduringtheblowmoldingprocess.Duetothehighblowmoldtemperatures,thematerialisstressrelieved,alignmentstressisneutralisedandthermalcrystallisationisincreased.PETmaterialdeformationathighertemperaturesisreducedbytheincreaseinther-malcrystallisation.Theso-calledglasstemperatureofthematerialrisesandenablesHotfillorpasteurisationwithoutsignificantbottledeformation.

Thebottleisflushedwithcoolingairpriortoextractiontostabilisethebottleintheblowmold.Thiscoolsitsufficientlyandpreventsdeformationduringextraction.

Special features of Blomax HR Series IIIOptionalfeaturesofBlomaxHRSeriesIIIenablehighprocessprecisionatmaximumspeeds.

Threedifferenttemperaturesarepossiblewiththethree-stagecooling/heatingsystem:• Onetemperatureforneckcooling• Amediumtemperaturetoinsulatethemoldcarrier fromthehotmold• Ahotoilcirculationtobringthemoldtotheoperating temperature

Thisthree-stagecooling/heatingsystemisdistributedtothevariousmoldcomponentsviaaringdistributor.

Thevalveblockcontainsablowingvalveandaircoolingvalves.Theyoptimisethereactiontimeandareinstalledadjacenttothebottle.Thecoolingairistransportedintothebottleusingahollowstretchingrod.Thesteelblowmoldsareheatedindividuallyforoptimalcontroloftemperature.

Blomax HR Series III – a profitable investmentTheuseofBlomaxHRSeriesIIImachinesincreasesthecost-effectivenessandreliabilityofHotfilllines.Theyalsocontributetothereductionincostsforpackagingunits:

• Optimaluseofmaterialthroughmechanical,cam- controlledstretching.Specificationsforwallthickness arepreciselycompliedwithandtheweightofthe productisreduced.• Optimalpost-heatingofpreformsviaheatingcontrol, whichmaintainsshortwavelengthsandenablesideal heatpenetration.• Flexibleconfigurationoftheovenensuresperfect temperatureprofile.• Optimalblowingairsupplydirectlybythebottlevia valveblocksandoptimisedlayoutofstretchingrodfor coolingair.

Blomax HR Series III: Hotfill

Maximum output during production(Machine availability: Blomax 4, 6, 8, 10, 12, 14, 16, 18, 20, 24)

Heating Stretching Heating Cooling (Weight of bottle in grams)

HR costs per bottle (CostsperthousandbottlesinEUR)

Preform

Neck crystallisation

Blow molding of bottle

11.3

4.5

37.4

10.8

29.8

20 21

Customisedbottlesforspecialapplications.Theseare,forexample,ovalPETbottlesforpackagingoffood,cosmeticsandcleaningagents.

«Exotic»bottlesarefrequentlyrequiredforcosmetics–thehighest-gradeproductsofferedinPETbottlesuntilnow.

Thecombinationofunusualshapesandoptimisedqualitypresentstechnicalchallenges.However,itisbynomeansimpossible,asKHSCorpoplastengineershavedemonstra-tedwiththedevelopmentoftheBlomaxPH.ThesuffixPHstandsfortheselectivepreformheating(PreferentialHeating)processdevelopedbyKHSCorpoplast.Theori-entatedpreformisheatedinapre-definedmannerfromtwosidesonamandrelwhichcanbelockedintopositionwithaguide.Thisresultsinacontrolled,optimisedanduniformmaterialdistribution.Cost-effective,lightweightovalbottleswithperfectappearanceandgeometrycanbeproducedwhichpreciselycomplywiththestipulatedspecifications.

Usingthistechnology,bottledesignswhichareaestheticaswellastechnicallydemandingcanberealised. •Qualityofappearance

•Optimisationofcapacity•Weightreduction•Possibleuseofpreformforlargerdiameters

Blomax PH Series III: Preferential heating

PH: Mandrel orientation

PH: Thread orientation in the mold

Preferential heating on orientated preforms

PH: Heating configuration

Rotating preforms in front of heating

Limits of the standard processes

•Insufficientmaterialdistribution•Results:thickening

andsectionswithlowresistance

Symmetricdevelopmentofblownmaterial

Rapidcontactbetweenmoldandbubbleatthe

narrowestpoint

Preferentialcoolingatcontactpointbetween

materialandmold:Materialnot

stretched;thickeningvisible

Application of Preferential Heating

Inthepreferentialprocess,theblownmaterial

developtowardsthecoolestareasDevelopmentofblownmaterialaccordingto

moldprofilewithuniformstretchingof

materialthroughallprofileareas

22 23

Blomaxstretchblowmoldingmachinesareheldinhighesteemgloballythankstotheirdurability,availabilityandreliableproductivitywiththelowestenergyconsumption.

Butoverthelong-termamachineisonlyasgoodastheservice.Andweareconvincedthatservicestartswiththeinitialcontact.Therefore,atCorpoplastwedonottalkaboutAfterSalesServicebutFirstMinuteService:Wegiveyouourcompleteknow-howrightfromthefirstminutes!Thisclosecooperationandserviceisgenerallyavailableovertheentireusefullifeofourmachines.

Servicenotonlyreferstomaintenanceandrepairs.Cor-poplastservicealsoincludesacompleterangeofproductssuchastraining,spareparts,molds,retrofits,Secondhandmachines, consultationandsupportfromourtechnicians–includingonsite.

Wearealsoproactivelyinformingyouaboutnewdevelop-ments,retrofits,energysavingandmaintenanceconcepts.

Themarketdemandsproductsolutionswhichcanbeimplementedquickly.Thankstocarefullysynchronisedtiming,CorpoplastcanprovideyouwithoperationalBlomaxmachinesatveryshortnotice.Minimumas-semblytimeusingprefabricatedsubassembliesandmo-dulesplaysanimportantrolehere.EfficientlogisticsandEDP-supportedprojectmanagementroundofftheprocess.

PersonalsupportfromyourCorpoplastcontactpersonguaranteesmaximumefficiencyinallorderphases.Ourcompanyphilosophyisbasedonnotsupplyinganymachinesuntiltheyhaveproducedtopclassbottlescon-formingtospecificationsduringthepre-deliverytests–andthenonlywiththepromisedproductionperformance.

Becauseofthesethoroughtests,allofourmachinescanberapidlyinstalled,setupandputintooperationafterdelivery.Allelectricalconnectionsaredesignedasplugconnectors–aseasyas«PlugandPlay».

Weoffertrainingbeforeandaftercommissioningforalltheoperatingandmaintenancepersonnelandalloperatingandmaintenancerequirements.ThisintensivetrainingprogrammebasedontheC.O.A.C.H.principle(Content,Organisation,Approach,Clients,Headlines)isanimportantpartofouroverallsupport.Wedonotregardtrainingasanauxiliaryservicetoaccompanythemachinedelivery,butratherasanessentialelementtoensurethesuccessfuloperationofyourBlomaxmachines.Trainingencompassesallrelevantareasoftechnicalprocessproce-dure,controlprogrammes,thecontrolvariablesforbottlequalityandproductionspeedaswellasprocessanderror

analysis,andtherequirementsforefficientpreventivemachinemaintenance.OurtrainingcenterinHamburghasanexcellentreputation.

Theparticipationofyouroperatingandservicepersonnelduringin-houseacceptance,commissioningandtestrunsofmachinesinCorpoplast’sassemblyhallisparticularlyeffective.Asaresult,customersarehighlyfamiliarwiththeprocesstechnologyandmachinehardware.Thisleadstoahighdegreeofidentificationbetweenthecustomer’spersonneland«their»machine–animportantrequire-mentfortrouble-freehigh-performanceproductionoffirst-classPETbottles.

Easy To Work With – the KHS Corpoplast Service

Training

Spare parts

Technical support

Bottles & Shapes™

TIP | Retrofits

Secondhand machines

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Ifnecessary,wewillaccompanyyouthroughoutaCorpo-plastmachine’sentirelifetime.Weinspectthemachineatregularintervalsandrecommendimprovementsaspartofourpreventivemaintenance.Wecheckoperatingandqualitydataanddiscusschangesinprocessdatawithyou–measureswhichcanimproveproductqualityandtheproductivityofthemachine.Refreshertrainingensuresthatnewpersonnelquicklybecomeaccustomedtothemachine,andthatpersonnelwhohavealreadyreceivedtrainingareconstantlyup-to-datewiththelatesttechno-logicaldevelopments.Machineoverhaulsandupgradesarecarriedoutatyourpremises.Evenoldermachinescan

bemodernisedbythereplacementofcomponentsoras-semblies,increasingtheirproductivityorreducingenergyconsumption.

Yoursatisfactionisourmainpriority–irrespectiveofthescopeofservicesyourequire.Youcanthereforealwaysexpectrapid,reliable,cost-effectiveservicefromus–tailoredtomeetyouronsiterequirements.

Inshort,ifyouneedus,wewillbethere.Withover90servicetechniciansworldwide.24hours–7daysaweek!

Weplaceutmostvalueontopprecision,qualityandrelia-bilityofspareandwearpartsforourBlomaxmachines.

AlwayslookforthesymboldisplayedherewhenusingsparepartsforyourBlomaxmachine.Itisoneverysparepartsdeliveryfromourcompany.PremiumQualityPartsfromCorpoplastforyourPremiumQualityProduction.

”You care for the content.We care for the filling and packaging.”

khS corpoplast gmbh & co. kg

Meiendorfer Strasse 203d-22145 hamburgphone: +49 (0) 40 679 07 0fax: +49 (0) 40 679 07 100e-mail: info@khs.comwww.khs.com

KhS PlaSmaxoptiMal barrier SolutionS for SenSitive productS

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High expectations of product quality The barrier of a plastic packaging determins, for which kind of beverages, liquid food or non food a container, e.g. PET, is applicable. All essential properties for a reliable barrier to preserve product atrributes of high quality juices, nonalcoholic beverages, beer, wine or lifestyle drinks such as „functional drinks“ are obvious:

The ideal barrier must be impermeable without reaction to the external environment or between the filled product and the packaging. Gases, like oxygen (O

2) and carbon

dioxide (CO2), that can migrate through the package wall,

will invariably deteriorate the taste of the filled product and diminish its shelf life. The vitamin C content of juices will be degraded and the product’s colour will change. Carbonated beverages, particularly in small bottles, lose their carbon dioxide content. Barrier protection must also be maintained at the highest possible level for a maximum period also under harsh climatic conditions to ensure that the packaging remains suitable for sensitive beverages.

Versatile PET PET is a plastic in big demand throughout the world on account of its virtually unrivalled benefits: light weight, transparent, not susceptible to shocks, economical to trans-port and totally recycable, making it the ideal packaging solution, especially for beverages. Optimized barrier pro-perties therefore ensure that PET materials can also be used to package particularly sensitive products to maintain their quality.

A competitive price for industrial mass production is another condition that a successful and effective barrier solution must fulfil in order to prevail on the market. At the same time perfect barrier properties must not impair the ability to recycle PET packaging on a bottle-to-bottle basis.

Crystal-clear arguments for PlasmaxThe coating methods used to meet all of these stringent demands are found in the revolutionary Plasmax tech-nology ensuring optimal, high-quality and flexible barrier coating of PET containers. This silicone oxide (SiO

x) barrier

thereby gives PET bottles properties which, in the past, were the exclusive domain of glass. Moreover, this method of-fers the following decisive advantages over other barrier solutions:

Food compatible: The Plasmax glass coating is completely inert, i.e. non- reactive and therefore safe. Since there is no contact be- tween the PET and the filled product, flavour scalping is eliminated. The permeation of gases and other sub- stances, leading to the loss of vitamins and discoloura- tion, are prevented so that the quality of the filled pro- duct is retained and shelf life extended.

Crystal clear: PET bottles with a Plasmax barrier are colourless and completely transparent to make it a very attractive proposition for marketing.

Ecologically safe: Contrary to multilayer and blend packaging, Plasmax- coated PET is 100 per cent recyclable and thus environ- mentally friendly.

Flexible and light: Plasmax-coated PET packages are not susceptible to shock and significantly reduce transport costs on account of their much lower weight, making them superior to glass bottles.

Efficient: Plasmax installations are particularly efficient and score top marks in terms of Total Cost of Ownership.

Versatile: In addition to beverage applications, the innovative Plasmax technology can also be used for liquid food such as ketchup and sauces, and significantly extends their shelf life. Furthermore Plasmax barrier enhances the application range of other plastics, including biode- gradable PLA.

Impermeable and invisible: Optimal product protection with Plasmax barrier

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PICVD plasma coating on the interior surface of the PET bottle

Optimized and patented:The coating process with the Plasmax

Reliable installationThe Plasmax machine is suitable for bottle sizes ranging from 100 millilitres to approximately 1.5 litres. The coating process is always optimally adapted to product-specific requirements.

Depending on the required barrier and bottle design, the Plasmax with its 12 rotating double-coating stations achieves an output of up to 12,000 bph. Its perfor-mance can be synchronized with the up-stream and downstream units, e.g. a stretch blow molding machine and filler.

As a result of its excellent process stability, the Plasmax machine guarantees an optimal barrier layer quality. All parts are readily accessible so that maintenance times are short, ensuring maximum uptime. In this manner the Plasmax can be perfectly integrated into a packaging line for utmost operating efficiency.

Schematic bottle travel through the Plasmax 12D (seen from above)

1 Bottleinfeed

2 Bottlesinglingstar

3 Loadingwheel

4 Turningwheel1

5 Coatingwheel

6 Coatingstation

7 Turningwheel2

8 Bottledelivery

9 Vacuumpumps

Plasmax in the focus of our clients

Consistant coating processThe Plasmax machine completes the coating in several steps: Each of the vacuum chambers is loaded with bottles. A vacuum is then applied and a reaction-gas mixture is introduced that transforms the gas into an energy-rich plasma state using microwaves to complete the reaction. Silicone oxide is deposited onto the entire interior surface of the bottle with a 10 to 100 nanometre transparent, impermeable layer.

Innovative technologyThe Plasmax machine uses the patented plasma impulse chemical vapour deposition (PICVD) process to coat the interior bottle surface with an extremely thin silicone oxide (SiO

x) protective layer to prevent the migration of gases

and other substances. The PICVD method ensures that all process parameters can be optimally adapted to the given bottle shape. It is applied to produce an effective and invisible coating, yet ensures that PET bottles remain fully recyclable.

„High barrier quality and easy operation of the Plasmax system is highly appreciated by Eckes-Granini and is convincing in the daily production process.”

Mario Dechent, Director Research & Development, Eckes Granini Group GmbH

“Our employees are enthusiastic about how easily the Plasmax equipment can be operated. They quickly became familiar with the machine and are proud to be the first to commercially use Plasmax in Switzerland.”

Pius Bernhardsgrütter, Chef d‘Exploitation Eckes-Granini S.A.

“As a converter we have the possibility to offer our clients absolutly transparent PET bottles with an optimal barrier protection for products like high quality edible oil with a Plasmax coating.

In future we see various application possibilities for products needing a trans-parent barrier PET bottle.”

Masaaki Ikezawa, General Manager at the R&D Center of HOKKAI CAN, Co. Ltd, Japan

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Capacity

bottle coating (bottles/hr) up to 12,000

Bottle dimensions

max. length (mm) 335

max. external diameter (mm) 100

volume (ml) 100 up to approx. 1,500

min. internal neck diameter (mm) 12

max. support ring diameter (mm) 48

Machine dimensions

L x W x H (m x m x m) approx. 6.1 x 6.2 x 4.2

number of coating stations 12 double stations

Plasmax 12D: Key features

Profitable PET refinement Expertise forms the basis, visionary ideas are the driving force: KHS Plasmax GmbH is specialised in high-quality barrier coating of PET packages using the Plasmax method. Apart from sales, the range of services includes application consultations and support of operating installations. The KHS Plasmax experts are backed by the ultimate PET competence of the KHS Group with their experience in the field of stretch blow molding machines.

Always one step ahead with PlasmaxThe Plasmax coating technology optimized by KHS Plasmax has significantly extended the areas of application of PET packaging: The process is being successfully used through-out the world by bottle producers and bottlers of sensitive, high-quality products.

Crystal-clear opportunities in future through PlasmaxCustomized solutions meet the ever-growing market require-ments: The products and concepts of KHS Plasmax are designed to ensure competitive advantage and quantifiable added value today and in future. This includes the further development of the innovative technology so that new trends and standards will also continue to be set in the future to take a leading position on the PET market.

Competence and close proximity to clients:KHS Plasmax GmbH

Capacity: up to 12,000 bph

Exact: precise control and monitoring of the coating process that is individually adapted to the given bottle design and product requirements.

Flexible: simple and quick changeovers; in-line operation within an entire bottling line or off-line operation with a bottle palletizer.

Economical: high uptime and efficiency rates

Readily accessible: well designed for simple cleaning and maintenance

User-friendly: fully automatic machine and process control for simple operation

Qualified: competent KHS Plasmax service and process support

Efficient: low, extremely competitive Total Cost of Ownership

Robust: coatings that are insensitive to the typical mechanical and thermal stresses encountered during bottle filling and transport

Approved: internationally approved by the authorities for the use of coated PET bottles for beverages and food

Furthermore: Transparent and 100% recyclable.

Global service The global service network of KHS Plasmax is tuned to the requirements of the highly developed Plasmax machines to ensure smooth, dependable production throughout their entire service life. Numerous branches and subsidiaries of-fer world-wide support in implementing innovative solu-tions. Our highly qualified service team ensures immediate support in the appropriate local language. Moreover, Plasmax machines are fitted with a modem / Internet router to enable KHS Plasmax service engineers instant access to the process for rapid remote diagnosis.

The facts favour Plasmax barrier: Food compatible, crystal clear, environment friendly, flexible, efficient and versatile.

Technical specifications

ReferencesA successful product speaks for itself. We have already furnished convincing proof of the efficiency and effec-tiveness of our Plasmax barrier technology in practice.

For further details please refer to the different application examples presented on the “References” page on our website:

www.valueaddedbottling.com

”You care for the content.We care for the filling and packaging.”

khS plasmax gmbh

Meiendorfer Strasse 203d-22145 hamburgphone: +49 (0) 40 679 07 0fax: +49 (0) 40 679 07 100e-mail: info@khs.comwww.khs.com