Trouble Shooting Manual ASBI

8/13/2019 Trouble Shooting Manual ASBI

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Optimize Primary Blow Delay (Start)

What Will It Achieve?

The purpose of the Primary Blow air is to inflate the preform as much as possibleto

the final shape of the container. The setting of the Primary Blow Delay time is one ofthe most critical processing adjustments that can be made in the molding process.Very small changes can have a significant effect on the container quality.There is no "correct" setting for Primary Blow Delay. The optimum setting willdepend on many other factors upstream of the stretch blow process and it is alsoimportant to understand that the optimum setting will change if one of thoseupstream conditions changes. Therefore adjusting the Primary Blow Delay timeshould be one of the last processing adjustment to be made when setting up amachine.!f Primary Blow Delay is too early the container may suffer from nec ringsor offcenter gates.!f it is too late the shoulder may show a grainy appearance there may

be a constrictionor the preform may split in the body.!f there is insufficient inflation in the primary blow the e#treme high pressure of thesecondary blow may cause damage to the inflating preform such as pearlescence inthe corners splitting in the base

What Must I Do?!t is nearly impossible to judge the effect of the Primary Blow air onthe inflation of the preform if the $econdary Blow air is also operating normally.Therefore the first step is to disable the $econdary Blow air after which the primary airtime setting can be adjusted to various settings to find the optimumHow Do I Do This?%eferring to the chart above&

1. !ncrease the setting of the $econdary Blow Delay timer to the same or more than

the Blow timer. This will prevent the $econdary Blow from taing place. 2. %educe the Primary Blow Delay time to '.' seconds. 3. $tart the machine allow the preform temperature to stabili(e then turn on the

blow mold. Tae a sample then increase the Primary Blow Delay setting for an)$B $eries machine this should be about '.'*+'., seconds per step. -ollect asample container at each step mar it and place it on a table. )t some point thecontainer quality will go bad typically this will be a constrictionmar around theshoulder area. There is no point in going any further once this happens and it ispossible that a stretch rod tip may be broen if you continue.

4. $top the machine and study the sample bottles produced it is liely that thequality will have gone through a range as shown by the red curved linesomewhere around the middle setting the best formed bottle will be seen. This isthe optimum setting for the Primary Blow Delay timer.

5. )fter the Primary Blow Delay has been optimi(ed you should then optimi(e the$econdary Blow Delay setting.

How Do I Do This?1. !ncrease the setting of the $econdary Blow Delay timer to the same or more than

the Blow timer.

1
http://var/www/apps/conversion/tmp/BottleFault/NeckRingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GrainyShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/ConstrictionASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PreformSplitShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/ConstrictionASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/OptimizeSecondaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/NeckRingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GrainyShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/ConstrictionASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PreformSplitShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/ConstrictionASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/OptimizeSecondaryBlowTimeASB.htm


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-hec the blown container if Primary Blow is woring correctly it should be'+/'0 blown.!f the preform comes out unblown then some part of the Primary Blow system1valve relay etc.2 is not operating correctly.

34T56 Tae care when using this procedure since the preform may become jammed

around the stretch rod and may damage the stretch rod tip.


The purpose of the Primary Blow air is to inflate the preform as much as possibletothe final shape of the container. The setting of the Primary Blow Delay time is one ofthe most critical processing adjustments that can be made in the molding process.Very small changes can have a significant effect on the container quality so anyfaults with the operation of the valves will create a major problem.

Ensure Primary Blow Is Operating

What Must I Do?

!t is nearly impossible to judge the effect of the Primary Blow air on the inflation ofthe preform if the $econdary Blow air is also operating normally. Therefore the firststep is to disable the $econdary Blow air.

Ensure Correct Preform Temperature Balance

2


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7ot P5T stretches more easily cooler P5T is more difficult to stretch.Therefore the primary method of adjusting the positioning of material in the finishedcontainer is to use relative temperature in various parts of the preform.!f the temperature is balanced the wall thicness of the container can be optimi(ed

and the overall strength of the container can be improved.!f the balance is incorrect some areas may become thic leading to a mottledorgrainyappearance while the thin overstretched areas such as the corners mayshow pearlescenceor crystalli(ation.

What Must I Do?

Balance the temperature of the material within the preform to give the most equalstrength in the finished product. 1see the additional information bo#2

3
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What Must I Do?


4


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How Do I Do This?

There are two major methods of doing this in an )$B $eries machine. !n the first method injection velocity is used to control the temperature balance ofthe preform. $ince most of the retained heat from the injection process is used in theblowing of the container this method can have dramatic effects on the finished

container. 8illing the injection cavity fasterwill have the effect of maing the shoulder

portion of the preform relatively cooler resulting in a container having athicer shoul!erarea and a thinner heel.

8illing the injection cavity more slowlywill allow less cooling time for the

shoulder area of the preform 1relative to the base2 leading to thinnershoul!ersand a thicer heel.

This method is more critical where the preform is relatively long. $horter preformsshow less response.The second method uses temperature adjustment at the conditioning station. Themethod of adjusting preform temperature depends on the type of conditioning

system fitted.

Conditioning Systems

4il 9 :ater -onditioning -ore :ith 5lectric 7eating Pot

5lectric 7eating -ore :ith 5lectric 7eating Pot

5lectric 7eating -ore :ith 4il 9 :ater -onditioning Pot

5lectric 7eating -ore :ith $plit Type 4il 9 :ater -onditioning Pot

Ensure Correct Preform Temperature Balance


7ot P5T stretches more easily cooler P5T is more difficult to stretch.Therefore the primary method of adjusting the positioning of material in the finishedcontainer is to use relative temperature in various parts of the preform.!f the temperature is balanced the wall thicness of the container can be optimi(edand the overall strength of the container can be improved.!f the balance is incorrect some areas may become thic leading to a mottledorgrainyappearance while the thin overstretched areas such as the corners may

show pearlescenceor crystalli(ation.What Must I Do?


5
http://var/www/apps/conversion/tmp/PreformCure/IncreaseInjectionVelocityASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/ReduceInjectionVelocityASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustCCore-HPotASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustHCore-HPotASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustHCore-CPotASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustHCore-CPotSplitASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/MottledBodyASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GrainyShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/HazinessASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/IncreaseInjectionVelocityASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/ReduceInjectionVelocityASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustCCore-HPotASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustHCore-HPotASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustHCore-CPotASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/AdjustHCore-CPotSplitASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/MottledBodyASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GrainyShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/HazinessASB.htm


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How Do I Do This?

There are two major methods of doing this in an )$B $eries machine. !n the first method injection velocity is used to control the temperature balance ofthe preform. $ince most of the retained heat from the injection process is used in theblowing of the container this method can have dramatic effects on the finished

container. 8illing the injection cavity fasterwill have the effect of maing the shoulder

portion of the preform relatively cooler resulting in a container having athicer shoul!erarea and a thinner heel.

8illing the injection cavity more slowlywill allow less cooling time for the

shoulder area of the preform 1relative to the base2 leading to thinnershoul!ersand a thicer heel.

This method is more critical where the preform is relatively long. $horter preformsshow less response.The second method uses temperature adjustment at the conditioning station. Themethod of adjusting preform temperature depends on the type of conditioning

system fitted.

Conditioning Systems

4il 9 :ater -onditioning -ore :ith 5lectric 7eating Pot

5lectric 7eating -ore :ith 5lectric 7eating Pot

5lectric 7eating -ore :ith 4il 9 :ater -onditioning Pot

5lectric 7eating -ore :ith $plit Type 4il 9 :ater -onditioning Pot

Additional Information3ote that strength does not only come from wall thicness it also comes from goodbi;a#ial orientation of the material and physical design of the container. Therefore acontainer having equal wall thicness may not always have the best overall strength.Thicer unstretched areas of the container may have a mottled bodyor grainyshoulderappearance.The conditioning station of an )$B machine is not intended to re;heat the preform sothe power and control is limited 1in most container designs2. The main purpose ofthis part of the machine is to provide a balancing function across multi;cavity moldsand in some cases it actually provides additional cooling.

Ensure Correct Preform "ol!ing Temperature


!t is essential that the average temperature of the preform is within the correct rangefor blowing the container. The optimum temperature will vary according to the si(eand shape of the container being molded and also the !.V. of the P5T resin but willtypically be in the range of /


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7aving the correct temperature will avoid problems such as6Too Hot1Preform does not reach strain hardening point27a(iness 1-rystalli(ation2>ate 4ff -enterPoor ?aterial Distribution 1-ircumferential2

Poor ?aterial Distribution 1)#ial2-rater 1Partial23ec %ings-onstriction@ensing 18isheye2$tretch %od Punches ) 7ole%educed Top @oad $trength%educed Burst Pressure $trength%educed Vacuum %esistanceToo Cold1Preform is stretched beyond the strain hardening point2$tress -racing

Preform $plitting :hen BlownPinholes A $plits !n The BasePearlescence 1-orners2Pearlescence 1>eneral2nderblown Detail5#cessive $hrinage 1@ow -apacity2

Refer the last graff

What Must I Do?

!n order to get the strongest container you should try to ensure that the inflated

preform is just reaching its strain hardening point at the same time as it is reachingthe blow cavity.

How Do I Do This?

:hile the machine is running gradually decrease the overall temperature of thepreform to a point where an even distribution of pearlescence starts to appear on thebody.4n an )$B $eries machine this can normally be achieved by one of the solutionsshown below.

4nce the container starts to show a little pearlescence raise the temperature slightlyuntil the pearlescence just disappears.

Possile Solutions

More Heat !e"uired #ess Heat !e"uired

%educe The !njection Time !ncreasing The !njection Time

%aise The -hiller :ater Temperature %educe The -hiller :ater Temperature7
http://var/www/apps/conversion/tmp/BottleFault/HazinessASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessCircumferentialASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessVerticalASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/CraterPartialASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/NeckRingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/ConstrictionASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/LensingFisheyeASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/StretchRodHoleASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowTopLoadGQASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowBurstGQASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowVacuumGQASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/StressCrackingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PreformSplitShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PinholesSplitsASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceGeneralASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnderblownCornersASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowCapacityGQASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/ReduceInjectionTimeASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/IncreaseInjectionTimeASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/IncreaseChillerWaterTempASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/ReduceChillerWaterTempASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/HazinessASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessCircumferentialASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessVerticalASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/CraterPartialASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/NeckRingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/ConstrictionASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/LensingFisheyeASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/StretchRodHoleASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowTopLoadGQASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowBurstGQASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowVacuumGQASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/StressCrackingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PreformSplitShoulderASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PinholesSplitsASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceGeneralASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnderblownCornersASB.htmhttp://var/www/apps/conversion/tmp/GQFault/LowCapacityGQASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/ReduceInjectionTimeASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/IncreaseInjectionTimeASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/IncreaseChillerWaterTempASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/ReduceChillerWaterTempASB.htm


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$ither

)djust The Temperature 4r 7eating Time !n The -onditioning $tation

#aziness $ Crystallization

Descri%tion

:hen held to the light the container is not perfectly clear a grey 9 white cloudinessis visible. This is a mild form of crystalli(ation that becomes visible in the blowncontainer even though the preform may appear to be clear.

Possile Causes &Causes are listed vertically in order of li'elihood and ( or easeof correction)

P5T %esin 3ot Dried -orrectly Preform Temperature Too 7igh:rong Type 4f Polymer Being sed

Ensure Correct Polymer Is In %se


There are two basic type of P5T polymer& their characteristics are given as follows6 Homo%olymer

-rystalli(e faster than co;polymers

7igher melting temperature 1appro#


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polymers cannot be distinguished visually.Dry the new resin as normal set barrel temperatures at a suitable level for the newresin. !n case of going from homopolymer to co;polymer the barrel temperaturescan be lowered by about *+=-. :hen changing resin in the other direction raisethe barrel temperature setting by the same amount.

%e;start the machine noting that some differences in stretch blowing characteristicsare liely so the primary blow delay primary blow pressure and secondary blowdelay may need to be re;optimi(ed 1among other settings2.

Additional Information

+,T$!t should be stressed that the differences in processing these two polymer types willbe virtually unnoticable in most cases. 4nly under abnormal conditons 1such as avery thic preform or a technically difficult container2 will there be any observable

differences.

&ate Off Center

Descri%tion

The gate of the preform is not in the center of the bottle base. There are manypossible causes of this fault.

Possile Causes &Causes are listed vertically in order of li'elihood and ( orease of correction)

Primary Blow !s Too 5arly $tretch %od $peed Too $low

$econdary Blow !s Too 5arly Preform !s Too 7ot

Bent Preform @owered !V 4f P5T

neven Preform :all Thicness Primary )ir 8low Too 7igh

neven Temperature )round Preform Broen 4r ?issing $tretch %od Tip

$tretch %od $topper !s Too @ong

Optimize Primary Blow Pressure


The purpose of the primary blow air is to inflate the preform as much as possible tothe final shape of the container. The setting of the primary blow pressure can beextremelycritical with containers having flat panelsalthough it is not normally soimportant for round containers.

9
http://var/www/apps/conversion/tmp/BottleCure/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/IncreaseStretchRodSpeedASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizeSecondaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectPreformTemperatureASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/BentPreformsASB.htmhttp://var/www/apps/conversion/tmp/GeneralFaults/LoweredIVASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenWallThicknessASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/ReducePrimaryAirFlowASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenTempASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectStretchRodTipASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/CorrectSettingOfSRStopperASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PanelsNotFlatASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/IncreaseStretchRodSpeedASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizeSecondaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectPreformTemperatureASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/BentPreformsASB.htmhttp://var/www/apps/conversion/tmp/GeneralFaults/LoweredIVASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenWallThicknessASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/ReducePrimaryAirFlowASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenTempASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectStretchRodTipASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/CorrectSettingOfSRStopperASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PanelsNotFlatASB.htm


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!f there is insufficient inflation in the primary blow the e#treme high pressure of thesecondary blow may cause damage to the inflating preform such as pearlescence inthe cornersor splitting in the base.Too much primary air pressure can cause uncontrolled inflation of the preformleading to splitting preforms or bucling of flat panels.

What Must I Do?

Turn off the $econdary )ir and test the inflation of the preform at varying PrimaryPressures.

How Do I Do This?

1. %eferring to 4ptimi(e Primary Blow Time increase the time delay of

$econdary )ir to the same as the blow time. This will prevent the secondaryair from starting so that the Primary )ir inflation can be more easily observed.

2. %educe the Primary )ir Pressure to around '.E+'.C ?Pa 1E+C Fg9cmG2 thenstart the machine.

3. :ait for the preform temperature to stabili(e then turn on the blow mold.4. -ollect a sample bottle mae a note of the pressure used then increase the

pressure by '., ?Pa 1,g9cmG2 and repeat the sample collection.5. -ontinue this until the pressure has reached around


11/45

center gatesand nec rings.!f there is too much delay between the introduction of the primary air and thesecondary air it may cause pearlescencein the corners of the container.

What Must I Do?

Before setting up the $econdary Blow Delay time the Primary Blow Delay settingshould be finali(ed. Then adjust the $econdary Blow Delay to the earliest possiblesetting without upsetting the blow;up of the preform.

Ref. old chart

How Do I Do This?%eferring to the chart above&1. )fter the Primary Blow Delay time has been setto give the best blown bottle

using Primary )ir only the machine should be re;started.

2. %educe the $econdary Blow Delay setting from its long setting to a setting ofabout '.*+'. seconds.

3. :hile blowing bottles decrease the $econdary Blow Delay setting in steps. 8oran )$B $eries machine this should be about '., second per step. -ollect asample container at each step mar it and place it on a table. )t first there willappear to be no or very little difference in the containers but on close inspectionyou should be able to see improvements in the definition of ribs logos andcorners. )t some point the container quality will go bad typically this will be anoff center gate or a nec ring. There is no point in going any further once thishappens and it is possible that a preform will split leaving fragments of P5T in themold if you continue.

C. 4nce the quality has turned bad slightly increase the $econdary Blow Delaysetting a little until the container quality comes good again. This is the optimumsetting for the $econdary Blow Delay timer

Correct Setting 'or Stretch o! Stopper


The stretch rod stopper sets the final gap between the stretch rod tip and the bottommold to ensures that the preform gate is trapped against the bottom mold but alsoensures that gate of the preform is not crushed too hard.!f the gap is too large off center gatesmay result wheras if it is too small e#cessive

stress may occur leading to stress cracing failures.

What Must I Do?

-hec the gap between the stretch rop tip and the bottom mold adjust the length ofthe stretch rod stopper accordingly.

11
http://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/NeckRingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/NeckRingASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/PearlescenceCornersASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/GateOffCenterASB.htm


12/45

How Do I Do This?

The procedure will vary slightly according to the specification of the machine 1-5 or

non;-5 mared machine2.1. Turn off the operation air and manually operate the valve for blow core downand stretch rod down.

2. Drain the remaining operation air from the system.3. Turn the blow mold select switch to the 488 position and operate the blow

mold close switch 1this will bring the bottom mold up but the blow mold willstay open2

4. -hec the gap between the stretch rod tip and the bottom mold. The gap should typically be around ,.' to ,.* mm or just enough to lightly pinch thematerial in the gate area


This adjustment is not applicable if the machine is operating with the over;stretchoperation 1champagne base2 activated.

Ensure Correct Preform "ol!ing TemperatureREF GR


!t is essential that the average temperature of the preform is within the correct range

for blowing the container. The optimum temperature will vary according to the si(eand shape of the container being molded and also the !.V. of the P5T resin but willtypically be in the range of /


13/45

$tress -racingPreform $plitting :hen BlownPinholes A $plits !n The BasePearlescence 1-orners2Pearlescence 1>eneral2

nderblown Detail5#cessive $hrinage 1@ow -apacity2

What Must I Do?

!n order to get the strongest container you should try to ensure that the inflatedpreform is just reaching its strain hardening point at the same time as it is reachingthe blow cavity.

How Do I Do This?

:hile the machine is running gradually decrease the overall temperature of thepreform to a point where an even distribution of pearlescence starts to appear on thebody.4n an )$B $eries machine this can normally be achieved by one of the solutionsshown below.4nce the container starts to show a little pearlescence raise the temperature slightlyuntil the pearlescence just disappears.

Possile Solutions

More Heat !e"uired #ess Heat !e"uired

%educe The !njection Time !ncreasing The !njection Time

%aise The -hiller :ater Temperature %educe The -hiller :ater Temperature

$ither

)djust The Temperature 4r 7eating Time !n The -onditioning $tation


) container made in this way will show the best strength however if the container

design has some details there may be a loss of definition.

owere! I*+*

13
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Descri%tion)lthough @owered !.V. is one of the most common molding problems it can also be one of the mostdifficult to diagnose. This is mainly due to the fact that the symptoms will vary according to the bottlebeing made and the severity of the @owered !.V.

7owever the following are typical preform 9 bottle faults that may occur.

e!uce Primary ,ir 'low


The purpose of the Primary Blow air is to inflate the preform as much as possibletothe final shape of the container.The setting of the Primary Blow 8low %ate is normally not so critical e#cept on largecontainers. Typically it will be left on its full setting and only adjusted in the case ofbalancing the air flow across multicavity molds.Too much airflow into the cavity may push the inflating preform away from the tip of

the stretch rod leading to off center gates. %educing the flow will assist in eepingthe preform in contact and eeping the gate centered. %educing the flow too muchhowever could lead to crateror the stretch rod punching a holethrough the gate ofthe preform.

What Must I Do?

!t is nearly impossible to judge the effect of the Primary Blow air on the inflation ofthe preform if the $econdary Blow air is also operating normally. Therefore the firststep is to disable the $econdary Blow air. $ee "4ptimi(e Primary Blow Delay" fordetails of how to do this.

How Do I Do This?

The system fitted to each model of )$B machine may differ slightly. 7owever mostmachines are fitted with one flow controller per cavity.!n a large machine with a multicavity mold it may be found necessary to reduce theflow to the center cavities only since the Primary Blow )ir flows into the center of themanifold.Tae samples off the machine blown only at primary pressure and adjust the flows toachieve equal blow up on all cavities.

nal Information

14
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15/45

djusting the flow controllers you will find that they only become effectiveey are less than *'0 open. 8rom *'0 to ,''0 open there is very littlee difference.

n .all Thicness (Circumferential)

Descri%tionThis fault is more common in containers that do not have optimi(ed stretch blowratios such as toiletries cosmetics and pharmaceuticals.These types of containers tend to be heavier than the optimum since the customerhas requested a container with a strong feel. $ince a thic preform will give anuneconomic cycle time it is preferred that the e#tra weight is added by increasingthe si(e of the preform. 7owever this in turn can lead to problems with neven :allThicness.


Preform Temperature Too 7igh neven Temperature 4f Preform

?aterial !V !s Too @ow Preform !s Too @arge 8or -ontainer

neven :all Thicness !n Preform

%ne-en .all Thicness (+ertical)

Descri%tion

?aterial thicness varies from top to bottom in the container.34T56 This characteristic is not always considered as a fault. The strength of acontainer comes from a number of areas that include& material thicness level oforientation and physical design of the container. There may be occasions when thethicness of the material varies but the strength of the container is oay. There mayalso be other occasions when the wall thicness has been optimi(ed but theresulting container has a reduced strength. Therefore to decide if this fault reallye#ists the container should be tested using a top load tester or a vacuum tester


Primary )ir Timing !ncorrect ?aterial !V !s Too @ow

Preform Temperature Too 7igh Preform !s Too @arge 8or -ontainer

15
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Preform Temperature Balance !ncorrect

Crater (Partial)

Descri%tion) large fold has appeared in the base of the bottle this type may be a largerdiameter than full crater.!t is caused mainly by incorrect preform temperature but improper settings in timersand air flow may also have some effect.


Primary Blow Timing !ncorrect neven Preform Temperature

Primary )ir Pressure !ncorrect neven Preform :all ThicnessPreform Body Temp. Too 7igh @owered !.V.

ow +acuum esult

Descri%tion

:hen a vacuum is applied to the container an unnacceptably low result is obtainedbefore total collapse of the container.+ote this fault only applies to those conditions where the vacuum test results havebeen correct but have now deteriorated and not to containers that have intrinsicallylow test results. >ood vacuum resistance is achieved by a combination of correct

processing but more importantly by good design and correct weight.


P5T %esin 3ot Dried -orrectly Bad :all Distribution 1Vertical2

P5T %esin Damaged By 4verheating Bad :all Distribution 1-ircumferential

+ertical Bars In 'ront $ ear Panels

Descri%tion

) vertical band of thic material generally in the center of any flat panels. !tHsappearance is obvious due to the different refraction of the light through the materialalthough it will virtually disappear after filling with a liquid. ?ost common in flat oval bottles.

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http://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectTemperatureBalanceASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/CraterFullASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenTempASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizePrimaryBlowPressureASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenWallThicknessASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectTemperatureBalanceASB.htmhttp://var/www/apps/conversion/tmp/GeneralFaults/LoweredIVASB.htmhttp://var/www/apps/conversion/tmp/GQCure/EnsureCorrectDryerOperation.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessVerticalASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/CheckMaterialHeatingSystemASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessCircumferentialASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectTemperatureBalanceASB.htmhttp://var/www/apps/conversion/tmp/scratch_5/CraterFullASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizePrimaryBlowTimeASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenTempASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/OptimizePrimaryBlowPressureASB.htmhttp://var/www/apps/conversion/tmp/PreformFault/UnevenWallThicknessASB.htmhttp://var/www/apps/conversion/tmp/BottleCure/EnsureCorrectTemperatureBalanceASB.htmhttp://var/www/apps/conversion/tmp/GeneralFaults/LoweredIVASB.htmhttp://var/www/apps/conversion/tmp/GQCure/EnsureCorrectDryerOperation.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessVerticalASB.htmhttp://var/www/apps/conversion/tmp/PreformCure/CheckMaterialHeatingSystemASB.htmhttp://var/www/apps/conversion/tmp/BottleFault/UnevenWallThicknessCircumferentialASB.htm


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Primary )ir Timing !ncorrect 4vali(ed -onditioning -ore %equired

Primary )ir Pressure !ncorrect Bad Bottle Design

ow Burst Pressure Test esult

Descri%tion

This test is normally only applied to -4< pressuri(ed containers such as those usedfor soft drins 9 beer etc.:hen a test pressure is applied to the bottle unsatisfactory e#pansion 1creep2 taesplace or complete bursting.+ote this fault only applies to those conditions where the burst pressure test results

have been correct but have now deteriorated and not to containers that haveintrinsically low test results. >ood burst pressure results are achieved by acombination of correct processing but more importantly by good design and correctweight.


P5T %esin 3ot Dried -orrectly Bad :all Distribution 1Vertical2

P5T %esin Damaged By 4verheating Bad :all Distribution 1-ircumferential2

Preform Too 7ot :hen Blown Bad Iuality P5T %esin

Stretch o! "aes , #ole Through The &ate

Descri%tion

During blowing the stretch rod punches a hole through the base of the preform.


$tretch 8orce Too 7igh Primary )ir 8low Too @ow$tretch %od Tip ?issing Primary )ir $ystem 3ot 4perating

Preform Temperature Too 7igh Preform Tip Design 3ot -orrect

Stress Cracing

Descri%tion

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$tress cracing will often lead to failures in burst pressure testing and normallyoccurs in the amorphous 1unstretched2 parts of the preform at the nec or in thebase adjacent to the gate.The fault may occur in any container especially those used for chemicals..!t can be observed as a "cra(ing" effect where minute multiple cracs may cause a

silver appearance in the material when light is refracted through it.


Preform $tretched :hen Too -old $tretch %od $topper !ncorrectly )djusted

P5T %esin 3ot Dried -orrectly -hemical )ttac

Confirm Chemical Compati/ility


Prevent the possibility of chemical attac causing stress cracing on the container.

What Must I Do?

-onfirm that all chemicals that come into contact with the container are safe for P5T.This includes contents rinsing agents and filling line lubricants among others

Correct Setting 'or Stretch o! Stopper


The stretch rod stopper sets the final gap between the stretch rod tip and the bottommold to ensures that the preform gate is trapped against the bottom mold but alsoensures that gate of the preform is not crushed too hard.!f the gap is too large off center gatesmay result wheras if it is too small e#cessivestress may occur leading to stress cracing failures.

What Must I Do?-hec the gap between the stretch rop tip and the bottom mold adjust the length ofthe stretch rod stopper accordingly.

How Do I Do This?

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19/45

The procedure will vary slightly according to the specification of the machine 1-5 ornon;-5 mared machine2.

1. Turn off the operation air and manually operate the valve for blow core downand stretch rod down.

2. Drain the remaining operation air from the system.

3. Turn the blow mold select switch to the 488 position and operate the blowmold close switch 1this will bring the bottom mold up but the blow mold willstay open2

4. -hec the gap between the stretch rod tip and the bottom mold. The gap should typically be around ,.' to ,.* mm or just enough to lightly pinch thematerial in the gate area


This adjustment is not applicable if the machine is operating with the over;stretch

operation 1champagne base2 activated.

String

Descri%tion

) fine fiber is e#tending from the gate of the preform around E' to ,*' mm in length.!t is liely that the fiber will become wrapped around the preform leading to ugly linesaround the finished bottle.


%esin 3ot Dried -orrectly 7olding Time Too $hort

7olding Pressure Too @ow 7ot %unner 3o((le Too 7ot

@ower ?old 4pening Too $low >ate Valve $ystem Defective

#azy ,ppearance In The Bo!y (Consistent)

Descri%tion

The preform has a grey or white ha(y appearance that is fairly consistent over theentire body. This may be very slight or may be so strong that the body is nearlyopaque. Typically the nec and the tip of the preform will be clear. Tae care not toconfuse this fault with ha(y swirls and clouds.

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20/45


7olding Time Too $hort %esin 3ot Dried -orrectly

8illing $peed Too $low -hiller Temperature Too 7igh

!nadequate -ooling :ater To !nj. ?old

#azy Clou!s 0 Swirls In The Bo!y

Descri%tion

The preform has a white ha(y appearance that is made up of streas swirls andclouds in some parts or the entire body. This may be very slight or may be so strongthat the body is nearly opaque. Typically the nec and the tip of the preform will beclear but in e#treme cases the swirls will appear here also. This fault will probablybe accompanied by stringin the gate. Tae care not to confuse this fault withconsistent ha(iness.!t is normal to see this fault on the first one or two shots after a start;up from cold

because decomposed material will have entered the cavity from the hot runner. Donotrecycle preforms since they will have a lowered !.V.

Sil-er Streas

Descri%tion

This fault is also nown as "$play ?ars" or "Jetting" in some companies. !t appearsas groups of multiple thin vertical streas of materal on the outside of the preform.

)s the light reflects off the streas they give a silver appearance. The streas areoften shaped lie a comet.!t is common to see this fault on the first one or two shots after a start;up from coldbecause decomposed material will have come from the hot runner. Do notrecyclepreforms since they will have a lowered !.V.

le Causes &Causes are listed vertically in order of li'elihood and ( orf correction)

ated ?aterial !njection Velocity Too 7igh

ent Drool ?aterial 3ot Dried -orrectly

e In1ection +elocity


Feeping the injection velocity low will reduce the shear that occurs in the material.$hear is a major factor affecting overheating of the material and !.V. reductiontherefore reducing velocity will protect the P5T resin from e#cessive damage. :hen woring with )$B $eries machines 1hot preform method2 the injection velocitywill also mae a significant difference to the material distribution in the finished

20
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21/45

container. 8illing slower means that the preform will be hotter when the mold opensand its temperature balancewill also have changed. Typically the shoulder area willbecome relatively hotter than the base area giving more stretch at the top of thepreform.5#cessive injection velocity can also disturb the alignment of the injection core

especially if the design is long and thin.%educing the injection velocity will also have the effect of maing the holding timeshorter since the V9P time will increase.:hen woring with PK $eriesmachines 1warm 9 cool 9 cold preform method2 thetemperature related effects are either greatly reduced 1P8 $eries2 or non;e#istent1PB A P? $eries2

What Must I Do?

4il flow into the injection cylinder must be reduced.

How Do I Do This?

8or machines fitted with electronic injection control reduce the velocity percentagevalue on the injection screen of the electronic injection control system. ?inimumusable value is typically around ,*+,0 but beware of maing a short shotat verylow settings.8or machines without electronic injection control reduce the setting of the valve V;* found on the operator side of the injection unit. Beware of maing a short shot atvery low settings.

Controlling # Pressure2 Drool 0 Sil-er Strea


34T56 ; This remedy is only applicable to those machines that use a sprue breafunction 1i.e. the injection unit moves bacward and forward during normal cycling toallow the @ower ?old to move2.-urrent and past machines that this applies to are&

)$B*' $eries

)$B,'' $eries

)$B


22/45

bacward or the injection mold opens to reduce and control fro(en gatese#cessivedrool and silver strea.7aving a small amount of drool at the interface of the 7ot %unner $prue and theBarrel 3o((le will ensure that a fresh piece of resin will e#ist at the time that thebarrel comes forward for the ne#t injection cycle.

?inimi(ing drool helps to prevent waste of material but has the adverse effect ofeeping the material static. Therefore during the time when the barrel is bac thematerial on the face of the 7ot %unner $prue is degraded but contact with humidityin the air then re;injected into the 7ot runner on the ne#t cycle. This can lead tosilver strea.

What Must I Do?

Timer settings need to be adjusted refer to the chart shown above. During holdingtime the plastic pressure inside the 7ot %unner will typically be in the region of E' +*' ?Pa. 1E'' + *'' Fg9cmG2. :hen the injection timer T'' finishes there is asequence of timers that are designed to allow some time for decompression insidethe 7ot %unner. 8our timers in particular have a large effect on drool.

T-- * In.ection /nit 0orward +eutralThis timer starts when timer T'' for injection times out. :hile it is counting thebarrel no((le valve 1VL*2 is ept on so that the no((le is forward with pressure.:hen TCC times out the valve VL* will return to neutral.

T12 * +o33le 4ac'ward Start2This timer starts when timer TCC times out. :hile it is counting the valve VL* willremain in the neutral position. :hen T'< times out the barrel no((le will start itsbacward movement.

T-5 * Shut*,ff +o33le Close StartThis timer starts when timer T'' for injection times out. :hile it is counting thebarrel shut;off no((le will remain open. :hen TCE times out the barrel shut;offno((le will be closed with pressure.

T15 * Screw Charging StartThis timer starts when timer T'' for injection times out. :hen T'E times out the

22
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23/45

screw rotation will start.

How Do I Do This?%eferring to the timing chart shown above tae note of the following points&

3o((le Bacward confirmation must not delay the opening of the mold

otherwise cycle time will be affected. 5nsure that there is a slight pausebetween the completion of the no((le bacward movement and the moldopening.

!ncreasing TCC will eep the barrel forward with pressure for more time which

will reduce the drool.

T'E must always be at least '.< second longer than TCE. !.5. the shut;off pin

must be closed before the screw starts to rotate.

!ncreasing TCE 9 T'E will increase the time available for pressure to

decompress in the 7ot %unner thereby reducing drool. TCE 9 T'E can have a wide range of settings provided that

i. The drool is not e#cessive 1minimum setting2ii. The screw is not delayed too much so that it delays the machine cycle1ma#imum setting2.

!f the drool is minimi(ed too far it is possible to end up with a quality problem on theproduct nown as $ilver $trea. This is normally seen as a fine double strea with ateardrop shape and is slightly silver in color.

!t does not always appear but it is more liely if the drool is near to (ero. !t may alsobe seen at start;up of the machine or due to other reasons since it is caused by

decomposed resin being injected through the 7ot %unner.:hen there is (ero drool the material that is e#posed at the 7% $prue during moldopen 9 close time is re;injected into the 7ot %unner. $ince this material has been athigh temperature in the presence of ambient air the P5T resin may be damaged byo#idi(ation and hydrolysis.

By creating a small amount of drool a flow of fresh material is maintained so thatwhen the no((le again contacts the 7% $prue the material in that area will have hadless e#posure.

Therefore if this phenomena is seen try reducing the timer setting of TCE 9 T'E a

little so that a little more drool is generated.

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Ensure Correct Temperature Of PET "aterial


!f the P5T material is too hot it will be damaged with regard to !.V. lossandgeneration of e#cessive ).).!f it is too cold crystals may not be broen down fullyleading to ha(y preforms and it will become more difficult to fill the cavity correctly.Feeping the temperature within acceptable limits will ensure greater stability ofmachine operation and container quality.

What Must I Do?

DonHt rely on the machine instrumentation in all cases. 7eaters instruments andsensors may suffer calibration or operation problems leading the operator to believethat all is oay. )dditionally settings of injection velocity and screw charge r.p.m.can change the actual melt temperature.The only way to be sure is to measure the actual melt temperature by conducting aseries of Hair shotsH and measure the temperature with an electronic thermometer.

How Do I Do This?

)llow the machine to run normally for at least ,* minutes maing preforms so thatthe barrel temperature stabili(es. $top the machine and quicly purge several shotsof material into a container. sing a probe or infra;red thermometer measure thema#imum observable temperature from the purged material.


!n a well set up machine it is normal to see a melt temperature around ,'+,*M-

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higher than the front barrel temperature as a result of frictional heating of thematerial. !f the temperature is


26/45


7olding Pressure Too 7igh $hort $hot 4n )nother -avity7ot %unner 3o((le Too -old %esin 3ot Dried -orrectly

Crystalline Streas Sprea!ing %p 'rom The &ate

Descri%tion

-rystalline resin e#tends upward from the gate for about


27/45


8illing $peed Too 8ast 8or 3ec Design P5T 3ot Dried -orrectly

Bloced Venting !n @ip -avities

Increase! ,*,* e-els

Descri%tion

)cetaldehyde is a colorless gas at room temperature it has a strong fruity smell. !toccurs naturally in many fruits and other foodstuffs and is used in the food industryas a flavor enhancer for certain products. !t is also generated during the productionand injection processing of P5T material. >enerally most acetaldehyde problemsoriginate in the barrel during the injection process.

34T5$ )ll P5T resins have some residual acetaldehyde after being manufactured

the quantity will vary according to the grade.

)cetaldehyde is only generated while the P5T resin is in its melt condition

therefore it can only be controlled by adjustments in the barrel 1/'02 and hotrunner 1,'02 of the machine.

The generation of acetaldehyde is not lined to moisture content of the

material although in the process of being dried acetaldehyde can also bedriven off. Therefore correct drying is also important for acetaldehyde control.


Barrel 9 7ot %unner 7eater 4verriding !nsufficient Temperature 9 )irflow !n Dryer

?elt Temperature $ettings Too 7igh !ncorrect -hoice 4f %aw ?aterial

!njection Velocity Too 7igh :orn 9 Damaged !njection $crew

$crew %.P.? Too 7igh

e!uce Screw *P*"


The speed of screw rotation will be reduced. This will prevent e#cessive shear andassociated frictional heating from ocurring. The end result will be better control ofacetaldehyde and protection of the material !.V.

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What Must I Do?

%educe the flow of oil going to the screw motor during screw charging time.

How Do I Do This?

4n machines fitted with five;step electronic injection control the oil flow to the screwis set as a percentage 1from '0 to //02. This is normally found on a differentscreeen to the injection parameters. ?ost systems use at least < or E steps of screwrotation speed. 3ormally the first is set very slow to give a smooth acceleration thethird 1if fitted2 is used to give a smooth slowdown. Therefore it is normally the secondstage that is used for the main part of the screw charging process. 4n machines without electronic injection control hydraulic valve V;/L found on thebody of the screw motor is used to control the oil flow. $crew the valve in a

clocwise direction to reduce the flow.

nal Information

justing hydraulic valves always tighten the locnut or screw to prevent thefrom changing.ng the screw %P? too far may lead an increase in the cycle of the machinecannot start the ne#t cycle until the screw is fully charged.

e The In1ection Screw (To Barrier Type)

What Will It Achieve?!f the injection screw is worn damaged or of an old design it may not be plastici(ingthe material correctly and may be creating e#cessive shear. This will lead to manyproblems incuding lowered !.V. increased ).). bubbles and unmelts.

What Must I Do?

8it a new screw to the machine. !f the old screw was a standard type then it shouldbe replaced with a "Barrier" type of the same length and diameter.

How Do I Do This?

8ollow the procedure given in the Training ?anual or the ?achine !nstruction?anual.

28


29/45


30/45

Pearlescence (Corners)

Descri%tion

This fault is more common in square or rectangular containers but may also be seen

in the heel area of a round bottle.Pearlescence is a silver;blue coloration that occurs when P5T is stretched beyondits strain hardening point. The strain hardening point will vary depending on the !.V.the preform temperature and the polymer type.


Preform Temperature Too @ow ?aterial !.V. !s Too 7igh

!ncorrect Preform Temeprature Balance !ncorrect Polymer Type

Primary )ir Pressure Too @ow Preform !s Too $mall 8or -ontainer$econdary Blow Too @ate -ontainer Design -annot Be Blown

Ensure Correct I*+ Of PET esin


sing the "correct" !.V. of P5T resin will mae it easier to produce a consistent highquality container.7aving the !.V. will avoid problems such as6Too #ow1Preform does not reach strain hardening point2>ate 4ff -enter

Poor ?aterial Distribution 1-ircumferential2Poor ?ateriial Distribution 1)#ial2@ensing 18isheye2-rater 1Partial23ec %ings-onstriction!n case of !.V. damage also see "@owered !.V."for more informationToo High1Preform is stretched beyond the strain hardening point2$tress -racingPinholes A $plits !n The BasePearlescence 1-orners2

Pearlescence 1>eneral2

Ref Stress strain daigra

Additional Information$mall changes in !.V. will have very little observable effect onthe container and in any case these small differences can generally be compensatedfor by optimi(ing the temperature of the preform. Therefore it is only really practical to

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consider major changes such as from @ow !.V. 1'.


32/45

There are times when it is unavoidable to use a preform which is too large or toosmall for a given container.8or e#ample where the customer has requested a heavy bottle with a small necdiameter then it is often necessary to design the preform larger than normal to eepa reasonable wall thicness. !n these cases it is necessary to try a cool preformat

blowing a high !.V. material or maybe both.-onversely where a customer has requested an e#tremely light weight containerwith a wide nec such as a jar then it is sometimes necessary to design a preformthat is technically "too small". !n this case a hotter preformcombined with a lower!.V.material may give better results

sign The Container $ Change Bottom "ol! Operation


There are some container designs that simply cannot be blown in P5T.

!n cases where the design is too e#treme it may be impossible to formthe cornerscorrectly or you may see pearlescence in the corners. )lternatively in oval bottles ifthe ovality ratio is too e#treme then there may be unnacceptable vertical barsofmaterial in the flat panels.

What Must I Do?

1. )void sharp corners in the design try to use the largest radius permissible inevery case. )void flat panels try to eep them radiused.

2. !n some cases bottom corner definition can be improved by using the "4ver

$tretch" or "-hampagne Base 4peration" system of the )$B machine.

How Do I Do This?

1. Design should be negotiated with the end user. 2. ?ost )$B $eries machines have the ability to change the sequencing of the

blow mold closing and the bottom mold up movement. 3ormally the bottommold moves up first but by setting a jump wire on the P@- it is possible tomae the bottom mold come up only after the stretch sequence has started.


Cham%agne 4ase &,ver Stretch) ,%eration-ontact your local )$B representative for details of how to do this on your machine. +,T$4nly certain molds can be operated in this way. se of an unsuitable mold may

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33/45

cause severe damage to your mold and your machine.

%n!er/lown Detail 0 Corners

Descri%tion

The detail or corners of the container have not been formed fully. This may appear inthe e#treme corners or in the vertical side corners. 5ngraving or logos will be poordefinition.

le Causes &Causes are listed vertically in order of li'elihood and ( orf correction)

ough !nflation By Primary Blow )ir 5ntrapment !n Blow ?old

ary Blow Too @ate ?aterial !.V. Too 7igh

m Temperature Too -old -ontainer Design -annot Be Blown

ary )ir Pressure Too @ow

,!e6uate +enting In The Blow "ol!*


The container blows to around /'0 of its finished shape within '.E+'.C seconds.This means that the air on the outside of the preform must be released throughrelativley large venting holes and slots with this time.

What Must I Do?:hen designing a blow mold mae allowances for venting in all corners and detail.

How Do I Do This?

7oles up to '.*mm and slots up to '.Emm should be used wherever there is apossibility of air being trapped.

Additional Information5ven though these si(es may appear very large due to the strain hardening of P5Tthere is little ris of bad appearance on the finished container.

se Secon!ary Blow Pressure

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The purpose of the $econdary Blow air is to mae the final shape of the containerwith all details. !f this air pressure is not high enough the container may not be fullyformed. This is especially important in containers having complicated rib designsengraving or a logo.

What Must I Do?

!ncrease the secondary air pressure supply.

How Do I Do This?

The )$B machine does not have any regulator for secondary air pressure. $omeusers install a regulator on the supply line just before the machine but in many cases

it will be necessary to adjust the pressure loading on the compressor itself. There is no point in running the compressor at ma#imum pressure for everycontainer it will simply be wasting energy. Try to adjust the compressor to theminimum pressure that will still achieve good formation of the bottle.!n a factory having multiple machines running from one compressor install aregulator on each machine to save energy.


?ost compressors cannot control the pressure e#actly the on;load 9 off;load range

may be as high as '.


35/45

Streas

Descri%tion

Vertical stretch mars most common in the shoulder area of the container. They areonly visible when the container is held up to the light.


Primary )ir Timing 3ot -orrect Preform 3ot $tretched $ufficiently

Primary )ir pressure 3ot -orrect

Pearlescence (&eneral)

Descri%tionThe bottle has a general appearance of pearlescence over most of its body 1not justthe corners2.Pearlescence is a silver;blue coloration that occurs when P5T is stretched beyondits strain hardening point. 1see Pearlescense !n -orners2 The strain hardening pointwill vary depending on the !.V. the preform temperature and the polymer type.


Preform Temperature Too @ow Preform !s Too $mall 8or -ontainer?aterial !V !s Too 7igh !ncorrect Polymer Type

Preform Splits .hen Blown

Descri%tion

The preform splits at some point during inflation. The body area may be partiallyblown.


Pimary Blow )ir Too @ate !ncorrect Preform Temperature Balance

Primary )ir Pressure Too 7igh Preform !s Too $mall 8or -ontainer

7eating Piece Too 7ot P5T %esin 3ot Dried -orrectly

Preform Temperature Too @ow

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36/45

'rozen &ate

Descri%tion

The gate of the cavity becomes bloced with cold material. This either happens atstart;up of the machine or between cycles.. The blocage stops the cavity from filling

on the ne#t cycle so one or more preforms will be missing. This fault may causeother cavities to have flash.


nmelt Blocing 7.%. 3o((le 7ot %unner 3o((le Too -old

-ondensation >ate Valve $ystem Defective

%esidual Pressure !n 7ot %unner

Sticing Preform

Descri%tion

Preform is highly distorted after injection mold opening. !n severe cases the preformmay stic to the injection core and be pulled up through the @ip -avities.

Possile Causes &Causes are listed vertically in order of li'elihood and (or ease ofcorrection)

!njection Time Too $hort !njection -ore -ooling !s Bad

Crater ('ull)

Descri%tion

) ring of material has formed around the gate area of the container typically this will be of smallerdiameter than a partial crater.!t is caused mainly by improper settings in timers and air flow but incorrect preform temperature mayalso have some effect.

Possile Causes &Causes are listed vertically in order of li'elihood and ( or ease of correction)

Primary Blow Too @ate Preform Body Temp. Too 7igh

Primary )ir $upply 8aulty Damaged 9 ?issing $tretch %od Tip

Primary )ir 8low Too $mall @owered !.V.

)$B -ontainer 7ome

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"ol!ing Solution (,SB)

Optimize Primary Blow Delay (Start)

What Will It Achieve?The purpose of the Primary Blow air is to inflate the preform as much as possibleto the final shape ofthe container. The setting of the Primary Blow Delay time is one of the most critical processingadjustments that can be made in the molding process. Very small changes can have a significanteffect on the container quality.There is no "correct" setting for Primary Blow Delay. The optimum setting will depend on many otherfactors upstream of the stretch blow process and it is also important to understand that the optimumsetting will change if one of those upstream conditions changes. Therefore adjusting the PrimaryBlow Delay time should be one of the last processing adjustment to be made when setting up amachine.!f Primary Blow Delay is too early the container may suffer fromnec ringsoroff center gates.!f it istoo late the shoulder may show a grainy appearance there may be a constrictionor the preform maysplit in the body.

!f there is insufficient inflation in the primary blow the e#treme high pressure of the secondary blowmay cause damage to the inflating preform such as pearlescence in the corners splitting in the base.

Ensure Primary Blow Is Operating


The purpose of the Primary Blow air is to inflate the preform as much as possibleto the final shape ofthe container. The setting of the Primary Blow Delay time is one of the most critical processingadjustments that can be made in the molding process. Very small changes can have a significant

effect on the container quality so any faults with the operation of the valves will create a majorproblem.

What Must I Do?

!t is nearly impossible to judge the effect of the Primary Blow air on the inflation of the preform if the$econdary Blow air is also operating normally. Therefore the first step is to disable the $econdaryBlow air.

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Trouble Shooting Manual ASBI

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