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

Uflex to build large flexible packaging plant in western India

September 30, 2014 10:01 am ET

Flexible packaging company Uflex Ltd. is planning a major new plant in the western Indian state of Gujarat.    More

Image

Malaysia's Scientex investing in PE, BOPP film capacity

September 30, 2014 9:51 am ET

Flexible packaging manufacturer Scientex Bhd, based in Malaysia, is planning investment of 300 million Malaysia ringgits ($91.4 million) over three...    More

Image

Asahi Kasei breaks ground on Alabama compounding plant

September 29, 2014 5:39 pm ET

Asahi Kasei Plastics North America will be able to solve two problems at once with a new compounding plant in Athens, Ala.    More

Image

Sigma's Packworx center geared at helping customers solve problems

September 29, 2014 3:41 pm ET

Sigma Stretch Film has opened a training center to help customers find the best solution to using the packaging films.    More

Image

DuPont shifting Teflon production in China

September 29, 2014 2:35 pm ET

DuPont Co. will spend more than $15 million to improve its fluoropolymer product offerings in China.    More

Market Reports

Plastics in Mexico - State of the Industry Report

This report analyzes the $20 million dollar plastics industry in Mexico including sales of machinery & equipment, resins and finished products.

Our industry analysis highlights macro industry trends and micro trends faced by companies that do business in Mexico. The report also provides key industry statistics and forecasts to anticipate future industry expansion.

Learn more

Plastics Caps & Closures Market Report

The annual recap of top trends and future outlook for the plastics caps & closures market features interviews with industry thought leaders and Bill Wood’s economic forecast of trends in growing end markets. You will also gain insight on trends in caps design, materials, machinery, molds & tooling and reviews of mergers & acquisitions.

Learn more

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

Upcoming Plastics News Events

January 14, 2015 - January 14, 2015Plastics in Automotive

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

June 2, 2015 - June 3, 2015Plastics Financial Summit - Chicago 2015

September 16, 2015 - September 18, 2015Plastics Caps & Closures - September 2015

More Events