KhS corpoplaStpackaging SolutionS and Stretch bloW Molding SySteMS for plaStic bottleS

02 03

4-5 Bottledesign

6-7 Bottledevelopment

8-9 LightWeighting

10-11 ConceptofBlomaxSeriesIII

12-15 HighlightsofBlomaxSeriesIII

16-17 Energyandcostsavings

Contents

18-19 Hotfill

20-21 PreferentialHeating

22-25 Service

Asatechnologypartnerofthebeverage

industrywith30yearsofexperience,

weknowthateachdecisionfora

stretchblowmoldingmachinestarts

withthequestionabouttheproductto

befilledandthecorrectpackaging.

Thisbrochuredoesnotthereforestart

withthefeaturesandbenefitsofour

BlomaxSeriesIIImachinetypesbut

withthewidevarietyoffilledproducts

andthewiderangeofPETbottles

producedwithourmachines.

Wewouldliketodemonstratehowand

atwhichstagewedrawonourcom-

prehensiveknow-howandtheservices

ofourtechnologycenteronthematter

ofBottles&Shapes.Thisreflects

howwedevelopyourperfectbottle

fortherelevantproducttobefilled.

Naturally,allsignificantdetailsregard-

ingourstate-of-the-artBlomaxSeriesIII

stretchblowmoldingmachinesarealso

included.Afterall,wealreadyconsider

thebestpossiblefurtherprocessing

methodsduringthedevelopmentphase

forexample,thedownstreamfilling

lines.Implementationofourknow-

howwithregardtoPETprocess,bottle

designandconstructionalsoplaya

decisiverolefortheallimportant

result,thatyourindividualpackaging

solutionwillmeetallyourrequirements.

Blomax Series III Stretch blow

molding machines a perfect solution

for all filled products

04 05

Hotfill

PrecisionPlasticsLtd.ThailandIVYTeaRoundRibbed0.5l27gBlomax16HRSeriesIII

Juice

Eckes-GraniniGmbH&Co.KGGermanyGraniniOrangeOrangeJuiceRoundChampagne1l39gBlomax18SeriesIII

CSD

Customer: BritvicSoftDrinksLtd.Country: UKProduct: TangoContent: AppleflavouredCSDShape: RoundBase: PetaloidVolume: 0.5lPreformweight: 28gSBM: Blomax12SeriesIII

Water

OAOKCRussiaIcevaPureStillWaterNotroundRibbed0.5l23gBlomax6SeriesIII

Tea/Energy/PLA

PLABrandsofAmerica,Inc.USABIOTASpringWaterRoundRibbed12oz/0.355l20.5gPolylactid(Corn)Blomax10SeriesIII

Beer

Customer: MoscowEFESBreweryZ.A.O.Country: RussiaProduct: SokolContent: BeerShape: RoundBase: PetaloidVolume: 1lPreformWeight: 42gSBM: Blomax8SeriesIII

Food/Non-Beverage

WeenerPlastikGmbH&Co.KGGermanyNiveaShowerCreamOvalInverted0.2l21.2gBlomax4PHSeriesIII

Milk

NMAGAustriaTrinkSnackYogurtCerealDrinkRoundChampagne0.5l26gBlomax12SeriesIII

EachfilledproductrequiresanappropriatebottleandthePETbottlecontributestotheimageofyourproduct.Atthesametime,thebottleshouldhavepropertiesthatenableittostayinshapeduringhigh-performanceproduction.Tomakesurethathappens,bottlesandmoldconstructionaswellastheentireproductionprocess,mustbeoptimallycoordinated.Ourcustomersbegintobenefitatthispointfromtheuniquetotalknow-howofKHSCorpoplast.

So,letyourimaginationreinfree.Wewillmakeyourbottledesignfitforproductionwhilealwaystakingintoaccounttechnicalandeconomicalfeasibility.

ThousandsofPETbottledesignshavealreadybeendevelopedatourHamburgtechnologycenter.Wecanthereforeassureyouwithconfidencethatwewillbeyourcompetentpartnertoimplementyourideasandwishes.

Ourprocedureisasfollows:Withour3DCADsystem,wewillfirstdemonstratehowyourideacanbeturnedintoyourfutureproduct.Allconceivableinfluencesonthebottlearedetermined,analysedandevaluatedatthispointinordertoachieveoptimalresults.

Wethencreateyourinitialprototypeonour3Dprinterwithinjustafewhours.

Inthenextstep,thefirstsamplebottleismanufacturedusingapilotblowmold.Thisisthentestedunderrealconditionsinourstate-of-the-artlaboratory,e.g.regardingbreakingandstackingstrength,wallthickness,burstingpressureandstresscracking.

Atthisstagewecanmodifyandoptimiseuntilallrequiredbottlespropertiesaremet.Thepathisthencleartomanufacturethemoldsaprerequisitefortrouble-freemassproductionofyourPETbottleswiththehighestguaranteedquality.

Bottles & Shapes: The contents determine the bottle

06 07

Top Load

Tolerances

Thermal Stability

Shelf Life

Creep

Micro-Biology

Stability of Grip Area

Burst Pressure

Impact Resistance

Stress Cracking

Stiffness of Base

Workgenerallycommenceswiththepackagingdesignproposalanimportantdetailofyourmarketingconcept.ThefirsthurdletobenegotiatedisthatnoteverybottleshapecanbemanufacturedusingPETwithstretchblowtechnology.Butjustabout!

TheKHSCorpoplastCADarchiveincludesapprox.12,000bottledesignsasignificantbenefitforourcustomers.Thankstoour30yearsofexperience,wecanadviseyoupreciselyanddevelopablowablebottlewhichcanbepro-ducedexactlytoyourrequirements.

Throughtheprocessofevaluatingtheproducttobefilled,thePETbottlesizeandshape,youwillgettoknowourtechnologycenterandtheKHSCorpoplastcorecompe-tencyandyouwillcertainlyappreciateourdefinitionofthesimpleconceptBottles&Shapes.Becausenowwewillstarttodeveloptheappropriatebottlewithyouwithoptimalpropertiesandthelowestpossiblemanufacturingcosts.Guaranteed!

Bottles & Shapes: From design to the perfect bottle

Fourareasdeterminebottledevelopment: DesignWeight Process Laboratory/tests

Thedesignincludes: Developmentandconstructionwithstate-of-the-art CADCATIAV5programs 3Dprototypingwithinhoursonour3Dprinter ProblemanalysisandsolutionsbasedonFiniteElement Analysis(FEA) Samplebottles

Theweightisbasedon: Preformdesigndependentonthestretchingratio LightWeighting,basedontechnicalandeconomical feasibility

Factorsinfluencingtheprocess: Highspeeds Lowblowingpressure Lowheatenergy AlternativematerialssuchasPLA(polylactid)or PP(polypropylenes)

Criteriaforlaboratory/tests:11mainpointsasdemonstratedonthesamplebottleshownhere.

Bottle construction 3D printer Top load tester

11 criteria for Laboratory/tests:

08

Theprincipleissimple:Weightreductioninbottleproductionleadstolowerblowingpressure,lessPETmaterialandreducedheatinginput.

Professionalimplementation:ToreducetheweightofyourPETbottle,yourequireacompetentpartnerwithcomprehensiveknow-howinPETprocessing.Wehavecompleteknow-howinanalmostuniquecombination:Intensiveresearchanddeve-lopmentinourtechnologycenterandclosecooperationwithMoldtecforthemanufactureofstretchblowmoldsandinjectionmoldingtools.

Becausewehave30yearsofexperiencein

PackagingtechnologyProcessknow-howPreformdesignBottledesignStretchblowmoldingtechnology

wecanguaranteethatLightWeightPETbottlesproducedonBlomaxmachinesalwaysmeetthedefinedspecifications.

AndLightWeightingcounts:WithaBlomax10SeriesIIIapprox.78,000,000PETbott-lescanbeproducedannually.Ifyousavejust1gramofPETmaterial(1kg=EURO1.20)perbottleatthisproduc-tionvolumeyoucansaveuptoEUR93,600!

Pneumatic stretching

Mechanical stretching

Bottles & Shapes: Light Weighting

Development in Light Weighting

PET quantityin grams

1.5 l CSD: reduced from 44 g to 31 g

0.5 l CSD: reduced from 28 g to 15 g

0.5 l water: reduced from 18 g to 12 g

Process stability

Base weight

Bottles producedYear 2000 2007

Target weight pneumatic stretching

Target weight mechanical stretching

01

02

03/11

04

05

07

08

09

12

1310

06

10 11

TheBlomaxSeriesIIIcancoveranareaof4to24cavitieswiththeunusuallypracticalmodulesysteminthefollowingsequences:

Room for individual solutionsTheoverallBlomaxSeriesIIIconstructionismodularindesign.Weusestandardisedsubassembliesforthemainmachinemodulessuchasthetransportmodule,linearovenandblowingmodule.Theheaterboxes,heatingtrainandblowmoldingstationsarealsomodular.Thisallowsustoofferyoucost-effectiveflexibilitywhenchoosingyourBlomaxSeriesIII.

Always the right moduleEquipyourBlomaxmachinewithexactlywhatyouneedtomeetcurrentandfuturerequirements.Thisisnopro-blemaseverymodulematcheseachmachine.Aspecialdesignsimplyconsistsofadifferentconfigurationofstandardmodules.Yourbenefits:NospecialmachineconstructionNoadditionalcostsforspecialdesignsShorterdeliverydeadlines

The modular system is economicalAllBlomaxSeriesIIImachinetypeshaveidenticalprocessengineering.Thishasenormousadvantagesforourcustomers.

Maximumflexibility:EachbottleproducedonaBlomaxcanalsoeasilybeproducedonanyotherBlomaxmachinetypewithoutlaboriousprocessadjustments.

Greatfamiliarity:OncetrainedonaBlomaxmachine,operationandmain-tenancepersonnelarefamiliarwithallotherBlomaxmachines.

Simplemaintenance:Therequiredsparepartsstockcanbereducedatourcustomersplant.Futuremodernisationorupgradepackagesgenerallyfiteachmachinesize.

Rapidsparepartsservice:KHSCorpoplastmanufacturesandassemblesmostmodulesregardlessofmachinesize.Thismeansflexiblereactiontorapiddeliveryrequirements.

Flexibility for individual components as wellThelinearovenisavailableinthreesizesbasedonthenumberofblowstations.Thelengthoftheovencanbealteredwithincertainlimitsbyshiftingthedwellpoint.Inordertomeetvariousheatingperformancerequirements,allthreelinearovenscanbecombinedwithanytrans-portorblowingmechanism.TheBlomax4,6and8haveaone-piecemachineconcept.Thismeansthemachineplatformisdirectlyconnectedtotheheatingmoduleorlinearoven.Anupgradeiseasythankstothemodularconstruction.Ifyouplanfutureexpansionswith

additionalheaterboxes,youshouldorderalargeroven.Theheatingtrainisthenadaptedtotheactualrequiredovenlengthbymountingthecorrespondingamountofmandrelcarriers.Youcanalsoproducebottleswithalar-gerneck(from36to49mmneckdiameter)ifrequiredatalatertimejustselectalargerpitchontheheatingtrain.

Theblowingwheelconsistsofaringtowhichtheblowmoldingstationsarebolted;theringisconnectedtothemachineplatformviaaballbearing.ThisringconstructionisidenticalforeachmachinepairintheBlomaxSeriesIIIandhasallconnectionpointsforeachtype.ThisnotonlyprovidesflexibilitywhenassemblingthemachinesattheKHSCorpoplastplant,butalsoenablesyoutoexpandyourBlomax4,10,14or18byafurthertwoblowmoldingstationsatyourplantandwithoutdisassemblingthemachine.Unlimited modularityMostmachinesaresuitableforaircargotransportbe-causeoftheirtransfer,heatingandblowmoldingmoduleconstruction.ThemaximumdimensionsofthemoduleshavebeendeliberatelydesigneduptotheBlomax16fortransportina747cargoplane.

Themachineiswiredupwithconnectorsbetweenthemodulesandtheintegratedcontrolcabinet(exceptBlomax4,6and8whicharebasedonaone-piecemachineconcept).

Thisenablessimplere-connectiononsiteagenuinePlug-and-Playinstallationrapidlycompletedincludingcommissioningandstart-up.Themodularconstructionisalsoeconomicalwithregardstomaintenance.Somecomponentscansimplyberemovedfromthemachineforadjustment,maintenanceorrepair.Thechangeovertimesare:1minforaheaterbox3minforaturningwheel30minforacompleteblowmoldingstation

01 Turningwheel

Loadingstation

02 Loadingstation

03 Loadingandunloading

wheel

04TransferstationI

Blomax Series III: The modular machine concept

Blomax 12 Series III

Blomax Series III machine key features(schematic)

05 Linearoven(smallestmachine)

06 Linearoven(largestmachine)

07 TransferstationII

08 Blowingwheel(smallestmachine)

09 Blowingwheel(largestmachine)

10TransferstationIII

11 Loadingandunloading

wheel

12 Bottleturningwheel

13 Electricalcabinet

Baseareaoflargestmachine

Baseareaofsmallestmachine

Transfermodule

Heatingmodule

Blowmoldingmodule

Blomax Series III compact Blomax Series III standard

4,6,8,10 4,6,8

12,14 10,12

16,18 14,16

20,24 18,20

12 13

OurcustomersbenefitfromKHSCorpoplastsdecadesofPETprocessexperienceandfromtheconstructionanddesignofstretchblowmoldingmachinesthatmeettherequirementsforthecost-effective,reliableandpreciseproductionofhigh-techPETbottleswithtopoutputandmachineavailability.

WecallthisValueAddedBottleBlowingahighdemandwhichismetbythekeyfeaturesofourBlomaxSeriesIIImachines.

1. Transport mandrels MandrelsandtheircirculationthroughthemachinearestandardcomponentsintheBlomaxSeriesIII.Throughcontinuousdevelopmentofthisreliableandhighlyefficientcomponentwithregardtodimensionalaccuracyandrepeatabilityduringprocess,thetransportmandrelprinciplesupportsaminimumprocesstimeparticularlyforhighspeedproduction.Impuritiesinpreformsandbottlesareavoidedbytheneck-downprinciple.

Blomax Series III: Highlights

2. Low energy consumptionThelowheatingandcompressedairconsumptionintheBlomaxmachinesisatraditionthelowestenergyconsumptioninthisindustry.

a)HeatingMandrelpitchonly38mmHighheatpenetrationofpreformsOptimaluseofheatingenergyFlexibilityofheatingmodulesCorecooling

b)CompressedairLowestdeadairvolumethroughvalveblockdirectly installedatthestationAirrecyclingfromP2toP1directlyintothe productionprocesswithoutcompromisingtheprocessReducedblowingpressure