Practical Guide to Blow Moulding

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1 Brochure More information from Practical Guide to Blow Moulding Description: Blow moulding is a manufacturing process used to form hollow plastic parts. It evolved from the ancient art of glass blowing and it is used to particular advantage with plastic materials. Celluloid was used first to blow mould baby rattles and novelties in the 1930s, linear low-density polyethylene was used in the 1940s for high production bottles and these days polyethylene terephthalate is used to make anything from soda bottles, to highly sophisticated multilayered containers and automotive fuel tanks in the last decade. When designing a product it is important to consider aspects such as a material's characteristics, the processing methods available, the assembly and finishing procedures, and the life cycle and expected performance of the product. This book presents the basics of blow moulding as well as the latest state-ofthe-art and science of the industry. A key feature is the approach of discussing the 'basics' and then taking the reader through the entire process from design development through to final production. It is very important for those involved in the manufacturing operation to keep abreast of the advances that are being made. This book will be of interest to those already using the blow moulding process and those who are interested in the potential offered by this versatile technology. About the Author Norman Lee has held various positions in the plastics industry in product and process design and development, in a career of over forty years culminating as Vice President of Research and Development with Zarn, Inc., USA. He has been active in the SPE in the Plastic Environmental (Recycling), Blow Molding and Product Development Divisions. He has written several technical reference books and been granted 20 patents in the field of blow moulding. Mr Lee is now directing his own consulting services, offering seminars and in-plant training programs for the blow moulding industry and conducting expert witness work. Contents: What is Blow Moulding? 1.1 Introduction Definition Basic Process History and Development 1.2 Types of Blow Moulding Introduction Stretch Blow Moulding Extrusion Blow Moulding 1.3 Material Considerations Materials Selection Product Properties and Market Usage 2 Design and Engineering 2.1 Design Product Design and Development System Process Management Tracking Systems 2.2 Basic Design Basic Design Considerations Bottle and Container Design Structural Design Design Details 2.3 Selection of Materials Polymer Principles Types of Polymers Amorphous and Crystalline Fundamental Properties 2.4 Characteristics For Blow Moulding

2 2.4.1 HDPE Acrylonitrile Butadiene Styrene (ABS) Polycarbonate (PC) Polypropylene Polyphenylene Oxide 2.5 Colouring Plastic Materials 2.6 Regrind Re-grind Specifications Process Performance Physical Properties 2.7 Post Consumer and Industrial Recycled Materials General Reading 3 Mould Design and Engineering 3.1 Main Characteristics of the Mould 3.2 Basic Design and Construction Considerations Mould Materials Selection of Materials Characteristics of Mould Materials 3.3 Cut Mould versus Cast Moulds Cast Aluminium Moulds Cut Moulds Cast and Cut Moulds 3.4 Importance of Fast Mould Cooling Fast Heat Transfer Material Considerations Manifolds Control of Flash Rate of Cooling Remedies for Flash 3.5 The Pinch Off Importance 3.6 High Quality, Undamaged Mould Cavity Finish Mould Cavity Finish 3.7 Effects of Air and Moisture Trapped in the Mould Polished Moulds Moisture 3.8 Injection of the Blowing Air Injection Blowing Air Blowing Devices 3.9 Ejection of the Piece from the Mould Ejection Methods Manual Ejection Automatic Ejection Hydraulic Systems 3.10 Pre-Pinch Bars Top Pinch Bottom Pinch 3.11 Bottle Moulds Neck Ring and Blow Pin Design 3.12 Dome Systems Dome Blow Pin Trimming Types 3.13 Pre-Finished System Pre-Finished Neck Rings 3.14 Unusual Problems Special Features Irregular Shaped Parts 3.15 Computer Aided Design and Engineering for Mould Making Application in Mould Making Systems and Methods 3.16 General Mould Buying Practices Mould Procurement

3 Request for Quotation 3.17 Mould Maintenance Program The Moulds Used to Produce Polyvinyl Chloride (PVC) and Polyethylene Terephthalate Moulds for PE Mould Cooling Lines Guide Pins and Bushings Striker Plates and Blow Pin Plates Pinch off Shut Down Acknowledgements Further Reading 4 The Extrusion Blow Moulding System 4.1 Extruder 4.2 Drive Motors 4.3 Gear Box 4.4 Screw Support Bearings Life of Thrust Bearings 4.5 Extruder Feed Feed 4.6 Hopper Feed Throat 4.7 Single-Screw Extruder Barrel Construction Zone Heating Venting Wear Resistant Barrels Grooved Barrels Pressure Generation 4.8 Melt Filtration 4.9 The Screw General-Purpose Screw Screw Zones Dedicated Screws Barrier Screws Wear-Resistant Screws Mixing Pins and Sections Distributive and Dispersive Mixing 4.10 The Extrusion Blow Moulding Head and Die Unit Centre-Feed Die Side-Feed Dies Wall Thickness Accumulator Head Die and Mandrel Die Swell Parison Adjustment Die Shaping Parison Programming Blow-up Ratio 4.11 Mould Clamping Systems Clamping System Requirements Clamp Operation Press Types 5 Extrusion Blow Moulding Advanced Systems 5.1 Co-Extrusion Blow Moulding Arrangement of Extruders for Co-Extrusion Multi-Layered Structures Co-Extrusion Systems 5.2 Three-Dimensional Blow Moulding

4 5.2.1 Introduction to 3-D D Extrusion Processes Suction Blow Moulding Parison Manipulation D Extrusion Systems Head Adapter Radial Wall System 5.3 Double Walled Parts and Containers 6 Injection and Stretch Blow Moulding Machines 6.1 Introduction Injection Moulding Process 6.2 Process Characteristics One step Machine Two Step Process Moulding Process 6.3 Tooling Introduction 6.4 Stretch Blow Moulding Introduction 7 Safe and Efficient Set-up, Start-up, Operation, Shutdown Procedures and Safety 7.1 Start-up Start-Up Preparations Melt Temperature Warming up an Empty Machine Warming up a Full Machine Initial Operation and Purging Commencing Moulding Manual Operation Commencing Moulding Automatic Operation Changing Conditions and Dimension Verification Recording Production Conditions 7.2 Safety in Normal Machine Operation Operation Safety Considerations 7.3 Shutting Down Temporary Stops Overnight Stops High Temperature Work Heat-Sensitive Materials Purge Materials Shutting Down an Injection Blow Moulding Machine Check Recommendations 8 Fault Finding Causes and Effects 8.1 Introduction 8.2 Troubleshooting 8.3 Brainstorming 8.4 Problems and Causes Background Sounds of the Plant Quality Problems Machine and Equipment Problems Importance of Consistent Material Process Settings Ambient Conditions 8.5 Preventive and Corrective Actions Corrective Actions Corrective-Action Team Root Cause 8.6 Packaging 8.7 Scrap Contaminated Material

5 8.7.2 Reworked Parts 9 Auxiliary Equipment: Design, Function, Operation, and Safety 9.1 Bulk Material Handling Systems 9.2 Dryer Hot Air Dryers Dryer Operation Dryer Safety 9.3 Blenders and Metering Equipment (Feeders) A Volumetric Blender Gravimetric Systems Metering and Blending Equipment Machine Operation 9.4 Machine Safety 9.5 Hopper Loader Loader Operation 9.6 Water Temperature Controllers Operation 9.7 In-line Inspection and Testing Equipment Laser Measurement Ultrasonic Testing Vision Systems Mechanical 9.8 Conveyors 9.9 Granulators 9.10 Safety 10 Finishing 10.1 Planning for the Finishing of a Blow Moulded Part Product Design Mould Engineering Process Planning 10.2 Removing Domes and Other Sections 10.3 Flash Removal The Cutting Machine Round Parts versus Parts with Corners 11 Decoration of Blow Moulded Products 11.1 Testing Surface Treated Parts 11.2 Spray Painting 11.3 Screen Printing 11.4 Hot Stamping 11.5 Pad Printing 11.6 Labels and Decals 12 Glossary Ordering: Order Online - Order by Fax - using the form below Order by Post - print the order form below and send to Research and Markets, Guinness Centre, Taylors Lane, Dublin 8, Ireland.

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7 Page 1 of 2 Fax Order Form To place an order via fax simply print this form, fill in the information below and fax the completed form to (from USA) or (from Rest of World). If you have any questions please visit Order Information Please verify that the product information is correct. Product Name: Web Address: Office Code: Practical Guide to Blow Moulding SC Product Format Please select the product format and quantity you require: Hard Copy (Paper Back) - Enterprisewide: Quantity USD 63 + USD 27 Shipping/Handling * Shipping/Handling is only charged once per order. * The price quoted above is only valid for 30 days. Please submit your order within that time frame to avail of this price as all prices are subject to change. Contact Information Please enter all the information below in BLOCK CAPITALS Title: Mr Mrs Dr Miss Ms Prof First Name: Last Name: Address: * Job Title: Organisation: Address: City: Postal / Zip Code: Country: Phone Number: Fax Number: * Please refrain from using free accounts when ordering (e.g. Yahoo, Hotmail, AOL)

8 Page 2 of 2 Payment Information Please indicate the payment method you would like to use by selecting the appropriate box. Pay by credit card: You will receive an with a link to a secure webpage to enter your credit card details. Pay by check: Please post the check, accompanied by this form, to: Research and Markets, Guinness Center, Taylors Lane, Dublin 8, Ireland. Pay by wire transfer: Please transfer funds to: Account number Sort code Swift code IBAN number Bank Address ULSBIE2D IE78ULSB Ulster Bank, Main Street, Blackrock, Co. Dublin, Ireland. If you have a Marketing Code please enter it below: Marketing Code: Please note that by ordering from Research and Markets you are agreeing to our Terms and Conditions at Please fax this form to: (646) or (646) From USA or From Rest of World

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