Stretch Blow Moulding Packaging Filling Labelling Conveying. KOSME KSB R KOSME KSB R ProShape KOSME KSB RG

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1 Stretch Blow Moulding Packaging Filling Labelling Conveying KSB R KSB R ProShape KSB RG

2 The KSB R series A high output per blowing station even for high output levels that is a main characteristic of the KSB rotary machines. With these machines fillers of smaller production batches can produce PET bottles in a broad range of sizes quickly and with a high output level. The KSB R series comprises compact, easily accessible machine models which offer great ease of use in daily operation. These reliable, operator-friendly machines provide you with a high degree of flexibility and an optimal price-performance ratio. The machines of the KSB R series produce bottles with a volume of 0.1 to 3.0 litres from a wide range of different preform types available on the market up to a neck ring size of 43 mm. Stretch Blow Moulding The KSB R series 2

3 System advantages Precise, high-performance bottle production Fast conversion in case of a product change-over Economic energy and compressed-air consumption Economic in investment and production costs Easily accessible machine design Air recycling Preform mounts with screening plates Stretch Blow Moulding The KSB R series System advantages 3

4 The machines of the KSB R series produce top-quality PET bottles and are economical in their energy and air consumption. For example, the module oven contributes to energy savings, which meet the most demanding standards with regard to cooling and preform settings. Energy efficiency can also be achieved with the optional air recycling system: The entire requirement for low-pressure air of the stretch blow moulding process is recovered from the main blowing air. As a result, the entire pneumatic system on the blowing wheel and the pre-blowing process when stretching the preforms is supplied by recycled main blowing air. Heating This means that a smaller compressor can be provided, which brings clear advantages for the total investment and the ongoing operating costs. The preforms and the finished bottles remain on one level during the entire production process. The preform infeed, preform heater, blowing process and bottle discharge are passed through without the deflection step. And this with just six transfer positions. Bottle output moulds provide for perfect containers or bottles exactly according to your specifications. Short change-over times are the advantage that makes the KSB R series a successful model. Even smaller bottle series are quickly produced. The fast change-over is especially ensured by the good access to all assemblies. The simple movement sequence of the machine minimises the maintenance required and the wear. Transfer from heating module to blowing module Stretch Blow Moulding The KSB R series System advantages 4

5 Method of operation Heating area Bottle transfer Stretch Blow Moulding The KSB R series Method of operation 5

6 Preform feed unit The preforms deposited in the hopper are routed into the roller orientor via a vertical conveyor. There the preforms are aligned hanging and routed into the feed ramp. Heating process The infeed starwheel picks up the preforms and transfers them to the preform conveyor belt. Now they run through the heating system while rotating continually. At the end of the heating section, an infrared camera scans the temperature of each preform and transfers this to the controller. This enables a temperature variance comparison and if necessary an automatic correction of the heating parameters is made. Blowing procedure This clamp inserts the preform in the opened mould, which is then closed and locked with control cams. The preform is sealed at the neck ring with a blowing bell. The stretching procedure is effected pneumatically via a cam control. After the blowing process has been completed, the mould is unlocked and opened camcontrolled. Bottle output A further rotating clamp at the output starwheel takes up the blown bottles and forwards them to the integrated air conveyor. For reasons of production safety, this is equipped with an automatic emergency ejector, which routes out incorrectly threaded bottles downward. The integrated handling system with preform grippers allows a quick change between various preform threads. A rotating clamp on the infeed starwheel picks up the preform from the heating system. Transfer belt through the heating zone Stretch Blow Moulding The KSB R series Method of operation 6

7 Assemblies in detail Touch-screen Patented heating module Preform feed rail Stretch Blow Moulding The KSB R series Assemblies in detail 7

8 Heating system Depending on size, 6 to 12 heaters with 8 or 9 radiators Patented adjustment system for exact positioning of infrared lamps from outside with oven closed for optimal heating of preforms Extremely energy-saving heating system with individual control of all radiators Solid transport chain with integrated preform gripper Blow-moulding station Circulation concept with mould hangers made of special alloy with low weight reduced centrifugal forces and wear Patented, fast-closing locking system for maximum production time Installation of blowing valve directly on blowing nozzle with option for use of air recycling for low air consumption Cam-controlled movement sequences of blowing station with mechanical functions for opening, closing, locking, unlocking, raising and lowering of bottom section Quick-change system for moulds Output: 2,000 containers/h per cavity Preform feed unit and bottle output Preform and bottle transfer with neckhandling system on one level without return sections Direct discharge to integrated container conveyor Operation and visualisation via touch-screen Central input of all parameters for preform and bottle types Password protection Monitoring of preform feed unit via touch-screen Mould Stretch Blow Moulding The KSB R series Assemblies in detail 8

9 KSB 4RG and 6RG specifically for large containers Machines with four or six blowing stations for manufacturing large containers Flexible machine concept for a broad range of products Production range for containers from 0.5 to 6.0 litres Transfer clamp for large containers Stretch Blow Moulding The KSB R series KSB 4RG and 6RG specifically for large containers 9

10 Transfer from infeed starwheel to conveyor Heating modules Serve many different markets with one machine concept: The KSB 4RG and 6RG product ranges consist of the production of large containers and the classic line of containers in small formats. With the greater pitch of the lashing belt and the larger dimensioning of the blowing stations, all variation options are possible. With the greater pitch of the machines and the adjusted speed for the tempering of the preforms, outputs of 5,000 to 7,500 con tainers/h are achieved. Bottle output Stretch Blow Moulding The KSB R series KSB 4RG and 6RG specifically for large containers 10

11 ProShape selective preform tempering Blow-moulding station Transfer Stretch Blow Moulding The KSB R series ProShape selective preform tempering 11

12 What can ProShape do? ProShape is a module for selective preform tempering. It enables you to produce oval and asymmetrical PET containers on a KSB R ProShape stretch blow moulder. This is how ProShape works: First the preform is heated evenly in the oven. Then a transfer starwheel transfers it to the ProShape module At the ProShape module, water-cooled aluminium plates reduce the preform s temperature on precisely defined areas. This way, the preform obtains an individual temperature profile which is tailored exactly to the blowing process and the final bottle shape. After a short equilibration time, it is transferred to the blowing station and blown to a bottle there. Orientation of preforms The ProShape module is also capable of exactly aligning preforms if the cap of the later bottle this requires. To do so, a camera system takes an image of each individual preform while it is still in the transfer starwheel. Based on the camera data, stepper motor exactly align the preform during transfer to the ProShape module or subsequently on the mould. Preform transfer after heating section Stepper motor for preform orientation Camera system for preform Stretch Blow Moulding The KSB R series ProShape selective preform tempering 12

13 ProShape your advantages High output Precise tempering for perfectly shaped bottles Enables considerable reduction in material used Round and oval on one machine ProShape module Stretch Blow Moulding The KSB R series ProShape your advantages 13

14 High output High speeds are no problem for ProShape: The process enables station outputs of up to 2,000 containers/h. Precise tempering for perfectly shaped bottles The ProShape process operates extremely precisely and allows only extremely small tolerances. This way, each preform obtains a precise temperature profile with exactly defined temperature zones. The result is precisely shaped bottles. Material savings ProShape also makes lightweighting possible for oval and asymmetrical containers, as thick and thin-walled areas can be located very close together, enabling stability with low weight. Round and oval on one machine If necessary, ProShape can be deactivated very easily. This way, you can change between standard production and ProShape as you like. Finished specially shaped bottle Stretch Blow Moulding The KSB R series ProShape your advantages 14

15 Technical data Number of cavities Max. output Max. capacity KSB 4R 4 8,000 bph 3.0 l KSB 6R 6 12,000 bph 3.0 l KSB 8R 8 16,000 bph 3.0 l KSB 4R ProShape 4 8,000 bph 3.0 l KSB 6R ProShape 6 12,000 bph 3.0 l KSB 8R ProShape 8 16,000 bph 3.0 l KSB 4RG 4 5,000 bph 6.0 l* KSB 6RG 6 7,500 bph 6.0 l* * bottle sizes > 5.0 l subject to technical verification by. Stretch Blow Moulding The KSB R series Technical data 15

16 Always at your side Extensive consultation on bottle design with design suggestions Precision mould construction Fast delivery of spare and wear parts Support by experienced specialists during commissioning Need-oriented training programme Remote diagnosis and remote support via VPN connection to Service Center Available worldwide: service technicians Stretch Blow Moulding The KSB R series Always at your side 16

17 Lamp adjustment for heating module Simple replacement of handling parts Air wall for media supply Stretch Blow Moulding The KSB R series Always at your side 17

18 Stretch Blow Moulding Packaging Filling Labelling Conveying Gesellschaft mbh Gewerbestraße Sollenau Austria Phone Fax kosme@kosme-austria.com Internet s.r.l. Via dell Artigianato, Roverbella Italy Phone Fax kosme@kosme.it Internet Subject to technical changes 09/13