Trouble-Shooting In Plastic Injection Molding Processes And Machinery

As with any manufacturing procedure, the processes of plastic injection molding can at times require a vigilant analysis and trouble-shooting methodology to ensure efficiency of the operation and end product quality. This article will provide an overview of some of the core components of plastic injection molding processes and machinery and an approach for trouble shooting. 

Efficiency throughout every phase of any plastic molding operation is fundamental to Quality Control and Quality Assurance. In order to effectively implement trouble-shooting methods for plastic injection molding machines, it is necessary to understand the full range of the processes, detailed criteria of those processes, the materials, and subsections and specifics of each. Though this is clearly a comprehensive topic, an abbreviated outline is being provided here for space considerations. 

Trouble-shooting plastic injection molding processes ultimately comes down to an analysis of four major components: (1) Material; (2) Mold; (3) Molding Cycle; and (4) Machine Performance. Additionally, in the practical world of injection molding, any existing problems tend to narrow down to the following three classifications: (1) Pre-molding; (2) Molding, and; (3) Post-molding. An outline of plastic injection molding machines, materials, and processes – as it applies to trouble shooting – generally consists of the following:

Molding procedures (i.e., extrusion blow molding, injection blow molding, etc.)

Different machine types and systems

Molding and finishing processes

Clamp systems

Feed systems

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How Extrusion Blow Molding Differs From Injection Molding?

If you operate a business that has a requirement for specially formed plastic bottles or containers, such as for juice and water bottles or liquid soaps and shampoos, it’s to your benefit to understand the various manufacturing processes for making those bottles and containers. What follows is an explanation of the extrusion blow-molding process and how it differs from injection molding.

Extrusion blow molding (EBM) is a manufacturing process whereby plastic is melted and extruded (that is, expelled to form a shape) into a hollow tube; a form or mold. (At this point of the process this material is generally referred to as a “parison,” which is a round melted mass that will then be molded; or formed.) The parison is held and sealed in the metal mold. Air is then blown into the mold thereby shaping it into the desired shape of the bottle or container. Once the plastic has cooled, the mold is opened and the part is discharged. There are two variations of extrusion blow molding: Continuous (with a constant extrusion of the parison) and Intermittent.

Injection molding (AmE or BrE), on the other hand, may seem similar but it is a different process. Injection molding is also a method of manufacturing products and parts by injecting material (such as plastic) into a mold. In this case, plastic in the form of pellets is melted and then injected (forced) into a mold where it cools and solidifies to the shape of the mold. The finished result is the exact copy of the mold.

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PET ALL MANUFACTURING INC.
85 Royal Crest Court, Units 1 & 2 Markham,
Ontario, L3R 9X5
Phone: (905) 305-1797
Email: cmerrick@petallmfg.com

Blow Molding Purging Procedures

Purging your blow molding machine is necessary to ensure optimal performance and a superior end product. While there are some differences between standard and custom blow molders, the blow molding design is similar enough that there is no real impact on the purging process. Even when it comes to extrusion blow molding vs. injection blow molding, purging is essential.

Safety First

If you plan to purge standard or custom blow molders, safety is the number 1 priority. Therefore, be sure that you follow all required safety procedures before the startup and shutdown, regardless of the material. You need to don the appropriate protective clothing, gloves, and eye-wear, and use a shield. If the machine has a vented barrel, clean the area around the plug and vent before sealing.

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Contact Details:

PET ALL MANUFACTURING INC.
85 Royal Crest Court, Units 1 & 2 Markham,
Ontario, L3R 9X5
Phone: (905) 305-1797
Email: cmerrick@petallmfg.com

Solving 3 Common Problems in PET Stretch-Blow Molding

PET or polyethylene terephthalate is commonly used as resin for stretch blow molding of bottles. Due to the nature of PET and various factors of the stretch blow molding machine, the occurrence of a few problems is inherent to the process. This blog discusses 3 of the most common problems which occur during PET stretch blow molding and their solutions.

Development of a Pearly Sheen and Haze (Whitening)    

If the PET is overstretched during the molding or is heated beyond 115 degrees Celsius during the injection or the blow stages, the formed bottle develops a distinct whitish tone. Since there are 2 different ways for the whitening to form, the whitening due to overstretching is called a pearly sheen and the one due to high temperature is called haze. In order to be able to prevent the development of the pearly sheen and haze, let’s understand the reasons for their formation. 

If the PET is overstretched while molding, its microstructure breaks up leading to the formation of a number of white circles which forms the pearly sheen. In order to solve this, the thin area which is affected should be cooled down and the part under the thin area should be heated so that the thin area receives a reinforcement of the material.On the other hand, haze forms when the temperatures reach beyond 115 degrees Celsius. At such temperatures, the molecules of PETA form crystals so as to achieve a lower energy state. Solutions range from lowering down the temperature source to increasing the ventilation.

Insufficient Top-load Strength 

Attempts to reduce the weight of the bottles are a common practice as it saves PET resin. However, such attempts often result in the falling of the top load strength below the required levels. The quality of the bottles then gets affected as they may break rather easily. To solve this, we have to realize that the bottles break at their weakest parts. These weak parts need to be replenished with more material in order to avoid insufficient top load strength. 

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PET ALL MANUFACTURING INC.
85 Royal Crest Court, Units 1 & 2 Markham,
Ontario, L3R 9X5
Phone: (905) 305-1797
Email: cmerrick@petallmfg.com

Injection Blow Molding (IBM) Machine: Know Your Part Well Before Sizing Machine and Tooling

The injection blow molding process is a good, reliable choice for producing challenging and delicate parts. Many factors need to be taken into account before purchasing the injection blow molding equipment, including technology and price.

Prior to selecting the blow molding resin, you also need to know the part’s specifications, the final weight, and the shot size. Typical IBM resins are HDPE, LDPE, PP, Nylon, etc. 

Cycle time and shot size affect the IBM machine’s output. To conservatively predict the IBM machine’s maximum output, assume 90 percent of its highest screw speed. The extruder should have a low melt temperature, as heat increases during the cycle time. 

Source: https://petallmfg.quora.com/Injection-Blow-Molding-IBM-Machine-Know-Your-Part-Well-Before-Sizing-Machine-and-Tooling

Contact Details:
PET ALL MANUFACTURING INC.
85 Royal Crest Court, Units 1 & 2 Markham,
Ontario, L3R 9X5
Phone: (905) 305-1797
Email: cmerrick@petallmfg.com

Advantages of Extrusion Blow Molding

There are a tremendous number of benefits associated with extrusion blow molding (EBM) for the manufacturing of plastic products.

• Revolutionary and Innovative Technology – Because companies can now better meet the demands of their customers for plastic ware, blow molding is considered an innovative form of technology. Not only is manufacturing using this type of extrusion blow molding faster, it allows for higher-volume outputs. That means that mass production of plastic goods is quicker and more cost-effective.
• Versatile – In addition to plastic containers that hold fluid, engineers have turned up the creativity level by designing a variety of unique applications and designs, including vehicle seal supports, flower pots, and fuel tanks, to name a few.

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Contact Details:

PET ALL MANUFACTURING INC.

85 Royal Crest Court, Units 1 & 2 Markham,

Ontario, L3R 9X5

Phone: (905) 305-1797

Email: cmerrick@petallmfg.com

Blow Molding: How It Works

Before going into detail as to how blow molding works, it helps to understand what it is. This manufacturing process is actually comprised of two parts. First is a parison, which is the starting tube made from molten plastic. The second part is the inflation of the tube, which is what molds the part or component into the desired shape.

This particular type of molding is used to make hollow plastic containers. Some examples include jars; containers; and bottles for milk, sports drinks, shampoo and conditioner, and so on. In other words, the containers that hold products used by millions of people around the world on a daily basis are created using this molding process.

This process offers many advantages. The blow molding method works well for creating complex shapes, production times are fast, and the empty plastic containers are recyclable.

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Contact Details:

PET ALL MANUFACTURING INC.
85 Royal Crest Court, Units 1 & 2 Markham,
Ontario, L3R 9X5
Phone: (905) 305-1797
Email: cmerrick@petallmfg.com