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32 packaging Netstal’s PET-LINE High-output production system for PET preforms Netstal’s PET-LINE system for the efficient production of PET preforms has undergone substantial development. The high-performance production system is now an even more refined piece of equipment offering the highest economic efficiency and level of customer benefit. Since its launch, PET-LINE has been further optimised and made more productive. The enhancements have been made possible by Netstal’s platform strategy and ongoing further development of all system components. Netstal is now presenting its PET-LINE 96 N based on the 3500 platform (3500 kN clamping force), equipped with a 96-imp. mould, newly developed by the Swiss mouldmaker Otto Hofstetter. At a cycle time of 9.6 seconds more than 36,000 preforms are produced per hour – an output hitherto unheard of in the context of a moulding machine of this size! Netstal’s platform strategy Netstal’s clearly-defined platform strategy for PET-LINE systems allows customers to specify their production systems to suit their particular requirements and capacity utilisation rates. One of the two basic system sizes (3500 kN and 6000 kN clamping force) provides the platform and The PET-LINE 96 N, as shown in Düsseldorf 2004: Machine different combination possibilities for mould sizes (24 to 144 cavities) and distances between cavities. Both systems are characterised by all of the attributes typical of Netstal such as speed, precision, reliability and robustness. The objective of the platform strategy is to produce preforms on the smallest possible system size with the highest possible number of cavities. From the customer’s point of view, a big advantage of Netstal’s platform strategy is the cost reduction per moulded perform, and the fact that the same system platform can cope with different PET applications. General requirements applying to PET high-output systems The demands imposed on highperformance systems are very complex, and clearly, all of the key characteristics of standard systems must be included equally in high-output systems. The same operating personnel, for example, must be able to run the equipment PET-LINE 96 N (3500-3550R) Cycle time ~9.5 seconds Moulded product 0.5 litre preform Output per hour 36,500 pieces Shot weight 1968 g Part weight 20.5 g Wall thickness 2.37 mm Material PET (INVISTA Polyclear 1101) Mould 96-imp. (Otto Hofstetter, Switzerland) Automation Netstal Chiller unit Furrer, Switzerland Special feature Direct colour injection (Repi, Italy) according to the same principles. In addition, the effort required to maintain the equipment must not be greater, and flexibility in deployment must be guaranteed (abiding by the principle of maximum capacity on the smallest machine basis). Furthermore, no compromises must be made when it comes to cycle times, the degree of production effectiveness and the preform quality. Alongside the absolute output rate, the lowest AA values (acetaldehyde) and a perfect distribution of the preform weights are essential for an efficient and profitable production. Innovation: PET-LINE 96 N A 96-imp. mould is now used on the small platform, 3500. This leads to a record production output for this machine size and represents a real innovation. The following development measures have been decisive factors in this increase in production: Optimisation on the machine side ■ ■ The intrusion (permanent turning of the screw) guarantees a very gentle plasticising of the PET material and an excellent homogeneity. The applied high-performance screw is laid out for a plasticising capacity of 750 kg/h and provides a gentle preparation of the melt with the least possible loss of energy. This preserves the material from excessive shearing and overheating and contributes markedly to a <strong>food</strong> spring 2005
further reduction of the acetaldehyde value. ■ The clamping force of 3500 kN available on the small platform permits the use of 96-imp. moulds for preforms with a thread diameter of up to 38mm. ■ The movement of the neck ring ledge is activated hydraulically. This enables the handing-over of geometrically very short preforms. ■ On the small platform it has been possible to increase the shot weight to 3400 grams. Enhancements on the mould side Otto Hofstetter AG has redesigned the 96-imp. mould so that it makes a major contribution towards the increase in efficiency of the complete production system. The mould features not only a new cooling water system with the slide bars and inserts cooled in parallel, but also self-lubricating guide bushes and slide plates. Thread slide opening can be effected hydraulically and the Direct Airblow Support (DAS) ensures a fast and reliable ejection for special preform sizes. The sum of these improvements has resulted in an enormous increase in the cooling capacity, so that yet shorter cycle times are possible and the consumption of cooling water is reduced by up to 50%. Apart from this, the new mould is very service-friendly and allows a high flexibility in the choice of preform geometry. Direct colour injection On its PET-LINE exhibit Netstal has also presented a newlydeveloped process for injection of the colour directly into the cylinder. The main advantages of this direct liquid colouring are better homogeneity of the material and more stable cycle times with the associated higher reproducibility. Applied additives such as acetaldehyde blockers, moreover, can develop a higher level of efficiency which translates, not least, into a certain level of cost savings potential. Conclusion Netstal’s PET-LINE is a mature preform production system which is perfectly established in the market. In combination with further developments and the newly designed 96-imp. mould of Otto Hofstetter AG it provides a package which offers the highest economic efficiency. This is the first time that a 96-cavity mould has been operated on the PET-LINE 96 N on the basis of 3500 kN clamping force, so that absolute record outputs are available from this machine size. The advantage for the customer is a substantial increase in production efficiency. ■
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