EFFECTS OF EXTRUSION BLOW MOLDING INTERNAL COOLING ...

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4 – CONCLUSIONS AND RECOMMENDATIONS The addition of Fasti internal cooling technology to the Bekum blow molder significantly increased production rates of the machine. Production increases as high as 22% were seen between conventional and Fasti molding methods despite limitations with our equipment including insufficient air-supply. An increased air supply would likely drastically lower the blow air temperature released from the Fasti unit. Decreased blow temperatures would result in more thorough cooling and more stable container properties. Dimensional analysis of containers proves that reduced warpage is a positive effect of internal cooling. The proof is found in the more consistent container diameter of Fasti containers, which is not associated with wall thickness. The thorough cooling and therefore setting of the body walls with low blow air temperatures reduced warpage after being released from the mold. Further proof of this could come from continued research upon implementation of a more reliable air supply. Fasti container formation resulted in a higher overall container weight which caused a reduction in volume. Without container and closure drawings it is difficult to determine if the container finish dimensions fell within desired tolerances but a low standard deviation among samples of the same manufacturing method displayed consistency and low standard deviation. Compression tested containers showed very little difference in performance that could be directly attributed to changes in crystallinity, container dimensions, or 44
wall thickness. Compression strength could be improved for certain applications by increasing wall thickness in the heel area. Study of the containers by Differential Scanning Calorimetry at various container locations reveals that the percent crystallinity of the container is independent of container wall thickness. Furthermore, the percent crystallinity did not appear to be dramatically affected by blow temperature. It should be noted that the tests were run on containers produced through short run times. Increasing the reliability of the air supply and therefore lengthening run cycles would produce greater sample sizes and allow more thorough testing. In summary, the Fasti internal cooling technology greatly increased output without making considerable changes to container performance. Any shortcoming found with the system can easily be programmed out with a combination of changes in processing temperatures, air flow, and parison programming. The positive effects of the Fasti system including reduced cycle times and reduced warpage would likely be magnified with the use of more air volume resulting in lower temperatures. 45
Page 1 and 2:
EFFECTS OF EXTRUSION BLOW MOLDING I
Page 3 and 4: Copyright by Kirk Alan Valko 2004
Page 5 and 6: TABLE OF CONTENTS LIST OF TABLES ..
Page 7 and 8: LIST OF TABLES Table 1. Fasti Cost
Page 9 and 10: Figure 24. Assembly Drawing........
Page 11 and 12: 1 - INTRODUCTION AND LITERATURE REV
Page 13 and 14: The process of extrusion blow moldi
Page 15 and 16: and dropped onto the conveyor, the
Page 17 and 18: Internal cooling is the process of
Page 19 and 20: pin is entering the bottle finish.
Page 21 and 22: 1.3.3 Costs Total cost of the unit
Page 23 and 24: Figure 7. Machine Surround Before F
Page 25 and 26: Table 2. Effect of Decreased Crysta
Page 27 and 28: 1.4.2 Wall thickness In addition to
Page 29 and 30: 2 - EXPERIMENTAL DESIGN AND TEST ME
Page 31 and 32: to determine the connection between
Page 33 and 34: 2.2 Experimental Methods 2.2.1 Samp
Page 35 and 36: Average temperature, checked by the
Page 37 and 38: Table 5. Bottle Body Dimension Tole
Page 39 and 40: D 2659, 1995). Twenty samples from
Page 41 and 42: Figure 15. Compression Data Example
Page 43 and 44: Figure 16. DSC Sample Pan Crimper T
Page 45 and 46: 3 - DATA AND RESULTS 3.1 Cycle time
Page 47 and 48: Table 7. Dimensional Test Result Co
Page 49 and 50: 3.3 Compression Strength Compressio
Page 51 and 52: Table 10. Percent Crystallinity of
Page 53: Table 12. Percent Crystallinity at
Page 57 and 58: performance tests. It would be desi
Page 59 and 60: 5.8 Optical Microscopy Optical micr
Page 61 and 62: 51 APPENDIX A Dimensional Results T
Page 63 and 64: 53 Table 15. Dimensional Test Resul
Page 65 and 66: Figure 18. Conventional Wall Thickn
Page 67 and 68: Figure 22. Fasti Wall Thickness 2 0
Page 69 and 70: Table 18. Compression Test Results
Page 71 and 72: Bekum Blow Molder Operating Instruc
Page 73 and 74: a) “SP1”(set point one) tempera
Page 75 and 76: i) Only one function may be used at
Page 77 and 78: ) Use Screwdriver to turn catch abo
Page 79 and 80: Figure 25. Detail 01 - Adaptor 69
Page 81 and 82: Figure 27. Detail 03 - Cooling Slee
Page 83 and 84: Figure 29. Detail 05 - Tip 73
Page 85 and 86: APPENDIX E Fasti Setup Experiment E
Page 87 and 88: Data Analysis Figures 31, 32, and 3
Page 89 and 90: Figure 31. Main Effects Plot for Fa
Page 91 and 92: BIBLIOGRAPHY ASTM Standard D2463-95
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EFFECTS OF EXTRUSION BLOW MOLDING INTERNAL COOLING ...

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