Blocked blow molding system offers energy savings

Jessica Hobrook

Published: February 27, 2012 6:00 am ET

Related to this story

Topics Packaging, Sustainability, Materials, Blow Molding, Molds/Tooling, Product News, NPE 2012

LAS VEGAS (Feb. 27, 12:05 p.m. ET) — With rising energy and material prices, many companies are looking for ways to cut costs without sacrificing quality.

KHS Corpoplast GmbH recently introduced its blocked blow molding system — a combination blower, filler, and capper unit that can be used in PET applications.

The InnoPet Blofill blocked system is designed to increase efficiency and cut costs, said Bj"ern von Lengerke, general sales manager for KHS, during a presentation at The Packaging Conference.

“You can blow your own package and you can fill it right away in line. By doing so, you can reduce the packaging costs and increase the advantages on the logistics side,” he said in a Feb. 7 presentation at the Las Vegas conference.

The system connects the blower directly to the filler and capper unit, cutting out the air conveyer, bottle rinser and other components. Instead, a multi-functional star wheel conveys the bottles from blower to filler by way of a transfer block. The block separates the dry blow molder from the wet filler and includes an airlock with constant air flow.

“You make sure the wet side, the humid side from the filling side isn’t entering the stretch blow molder, because the stretch blow molder doesn’t like that,” von Lengerke said.

The base system can be used for water or other non-carbonated soft drinks and can make up to 72,000 bottles per hour.

With some modification, the system can also be used for carbonated beverage applications and hot fill applications at 185-190° F.

A cooling system – a star wheel equipped with a set number of spray nozzles – can cool bottles bases from approximately 167° F to 131° F. This eliminates the risk of stress fracturing, which is a common deterrent to using blocked systems, von Lengerke said.

“There are less and less arguments against blocked systems like this,” he said.

The cooling system can be modified based on production needs, is efficient and has low water consumption, he added.

The Blofill blocked system can make several bottle types at maximum speed, giving users a flexibility that was not available with previous blocked models, von Lengerke said. New heating technology also cuts down on start up time and reduces pre-form losses.

Temperature restrictions can make the system difficult for some hot fill applications in the US, but with some adjustments can be used for a variety of juices, teas, and other drinks, he said.

Because blocked systems like the Blofill eliminate the traditional air conveyer, they have several advantages over standard systems, von Lengerke said.

The machine can handle delicate light-weight pre-forms, even in hot-fill applications. The design also saves space and uses less energy, an important consideration in plants in Europe and Asia, and companies can save on human resources costs because the system only requires one operator, he said.

The blocked blower and filler unit may be less efficient than separate blower and fillers, but standard lines are limited by their least efficient component – often the air conveyer, von Lengerke said. In these cases, blocked systems can be more efficient than traditional ones.


Comments

Blocked blow molding system offers energy savings

Jessica Hobrook

Published: February 27, 2012 6:00 am ET

Post Your Comments


Back to story


More stories

Image

Plastics industry blasted for stance in green building debate

July 22, 2014 2:45 pm ET

The plastics industry has taken high-profile stance in the debate over green building standards. The result, today at least, is that it's getting...    More

Image

Plastics help designers bring home the gold

July 22, 2014 2:15 pm ET

Products with polymer content received multiple gold recognitions in the 2014 International Design Excellence Awards.    More

Image

Evolving with the times helps Ohio's Midwest Elastomers prosper

July 22, 2014 12:53 pm ET

Midwest Elastomers Inc. is 35 years old this year, and if the company hadn't abandoned its roots and evolved, it long ago could have gone the way of...    More

Image

DSM planning North American nylon plant

July 22, 2014 11:41 am ET

Materials firm Royal DSM NV plans to build a new nylon resin plant in North America, but no decision has been made on the plant's exact location.    More

Image

Beer maker Carlsberg enlists suppliers for 'upcycling' project

July 22, 2014 11:14 am ET

Carlsberg Breweries A/S in Denmark has started an ambitious project with its suppliers to optimize its packaging for the purpose of “upcycling.&...    More

Market Reports

Injection Molders Market Report & Ranking 2014

This special package contains our 132-page 2014 Market Report on the Injection Molding segment and our exclusive 2014 RANKINGS database of 500+ Injection Molders for a discounted package price.

Learn more

Plastics Recycling Market Review & Outlook 2014

This special report from Plastics News examines the North American plastics recycling industry and provides insight into indicators that impact market viability, including Resin pricing trends for virgin and recycled market material and historical Resin production trends for post- consumer and industrial waste.

Learn more

Shale Gas Market - Analysis of North American Region

This report highlights the impact of shale-based natural gas on the North American plastics market and features an in-depth analysis of production trends in the United States during 2013 and a forecast for 2014 and beyond.

Learn more

Upcoming Plastics News Events

September 10, 2014 - September 12, 2014Plastics Caps & Closures 2014

February 4, 2015 - February 6, 2015Plastics News Executive Forum 2015

More Events