The global polymer nanocomposites market will reach $11,549 million, in terms of revenue and 6,014 kilo tons corresponding volume by 2022, registering revenue growth of 10.9% during 2016 - 2022, as per Allied Market Research.
North America held about 33% share in the global polymer nanocomposites market in 2015, and is expected to maintain its lead during the forecast period. The dispersion of nanofillers in polymer matrices are known to enhance the physical, mechanical, and barriers properties of the material. These enhanced properties make them more beneficial for use in industrial sectors such as construction, packaging, electrical & electronics among several others. Increasing use of polymer nanocomposites in the automotive as well as packaging industry and the stringent government regulations for automotive emissions in several countries such as the U.S., Germany, India, and China is invariably supporting the growth of global polymer nanocomposites market. On the contrary, high cost of processing is dampening the market growth. The growing consumption of graphene and related materials would drive the future growth of the market. The nanoclays segment generated three-fifths of overall revenue in 2015, owing to its flame retardant, mechanical & barrier, dispersion properties, and reduced weight. Furthermore, the segment is projected to be the fastest growing, at 11.8% CAGR during 2016-2022. Carbon nanotubes segment follows nanoclays at second place. Polymer nanocomposites find application in construction, automotive, electrical & electronics, packaging, and biomedical & defence among others. Automotive is the fastest growing application, registering a CAGR of 11.4% during 2016-2022 owing to the lightweight properties and high durability and strength of polymer nanocomposites. The rise of electric vehicles has invariably risen the demand for polymer nanocomposites. Key findings of the study
North America and Europe collectively generated more than half of the total polymer nanocomposites market revenue in 2015; however, Asia Pacific and LAMEA shall collectively churn away about 2% of the revenue by 2022. Stringent government regulations imposed on vehicular emissions and rapid adoption polymer nanocomposites based materials in the packaging sector are the key factors responsible for market growth in these regions. However, LAMEA is projected to be the fastest growing segment during the forecast period.
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Wednesday, October 19, 2016
Global demands for Nanocomposites to reach US 11.6
Tuesday, October 11, 2016
Latest Injection Molding Machine Technologies
Injection molding machines divided into three categories based on technology used:- Hydraulic
- Hybrid
- All electric
Hydraulic Injection Molding Machines
Hydraulic machines are old fashioned machines consume more energy. In hydraulic injection molding machine hydraulic system is used to injection, mold open and close, and clamp pressure. In earlier versions of hydraulic systems contactors were used to on and off the motor. It means there were only two positions either motor is fully on or off. Motor runs at full speed even low pressure is required. When low pressure is required a pressure relief valve is installed to control the pressure. The largest hydraulic press is available in 7000 tons.
All Electric Injection molding machine
A new technology introduced in injection molding machines is All Electric injection molding machines. This technology is energy efficient and more presie and oil free. It is absolutly new technology used in injection molding machines. It usesis directly electric enegry to presses, open and close mold. This new technology is more efficient than hydraulic in which 20% to 30% energy is wastes in two converstions 1st electrical power to hydraulic and then 2nd from hydraulic power to mechanical power. Servo motor technology is more precise than inverter and AC motor both are used for same surpose to reduce or control the speed of motor. The largest all-electric press available in 3300 tons.
| Difference | All-electric | Hydraulic |
|---|---|---|
| Precise | High | Less than All-electric |
| Repeatability | Good | Not as good as All-electric |
| Noise level | Very low 60 db | High |
| Price | High | Less than all electric |
| Hydraulic Oil | Oil free | Used |
| Motors used | Servo | Inverter/AC or DC |
| Maintenance | Less maintenance required | High maintenance due to hydraulic |
In all-electric IMM all functions like clamp and injection are done by the servo motors.
Servo motors
Servo motors are generally an assembly of four things:
- DC motor
- gearing set
- control circuit
- Position-sensor (usually a potentiometer)
The position of servo motors can be controlled more precisely than those of standard DC motors, and they usually have three wires (power, ground &).Servo motors are equipped with an encoder, feedback system. Didvided into two catagories.
- AC servo motors
- DC servo motors
Hybrid Injection Molding Machine
Complete hydraulic injection molding machine and all electric molding machine have their advantages and disadvantages. As all-electric breakdown maintenance is very costly. To overcome this a hybrid injection molding machine itroduced. Hybrid IM machines have the advantages of both all-electric and hydraulic machines. In hybrid except injection and clamping all other functions are performed with hydraulic. Hybrid IM machine is relatively cheaper than all-electric and expensive than hydraulic injection machine.
High Precise Injection Molding machines (IMMs)
Injection molding machines maker claims that their Injection molding machines are highly precise and highly energy saving machines. So if you want to buy a new IMM then how to decide and choose an injection molding machine which is precise according to your requirement.
If you have visited the market or searched online then you will be well aware of servo drive injection molding machine and all-electric injection molding machines.
Servo technology makes an injection machine highly precise and energy saving machine.
Injection molding machines are divided into three types on the base of technology used.
Hydraulic IMMs
All-electric IMMs
Hybrid IMMs
In old fashioned injection molding machines, hydraulic system used was not energy efficient not the motor used to drive the hydraulic system was precise. Motor for hydraulic pump runs all the time even when machine not doing any work. Then what happen with hydraulic oil, hydraulic oil circulates in the pump relief valve and back to hydraulic oil tank without doing any work. Relief valve also cause heat generating in the oil so a new cooling system is required to cool the hydraulic oil.
IMM maker introduced changed and improved hydraulic system that turn of the motor completely or slow down the speed of motor according to requirement.
Motors used for this purpose are not much precise. These motors can run at full speed, slow and turn off but not precise.
So to counter this situation a new drive system introduced named servo motor and servo drive. Servo drive is used in places where high precision is demanded like CNC machines. Servo technology have feedback and encoder and location sensor.
Now a days servo drive system is using in Injection molding machines that make them more precise and energy efficient along with PLC and HMI for better control and to attach with supervisory control. PLC and HMI can be connected with computer via Ethernet cable in the premises or any computer with internet.
All-electric injection molding machines there are servo drive system to control each and every motion of the machine like clamping, injection and retraction etc. hydraulic is completely removed from all-electric Injection molding machines. This new all servo drive system had made injection very precise, energy saving and a very clean injection molding process oil free cleanroom friendly.
Servo drive system available for low tonnage injection molding machine for high and ultra-high tonnage you still have other systems. All-electric injection machines are expensive and available in small and medium size. To overcome this situation hybrid injection molding is introduced which have advantages of both hydraulic and all-electric.
Extrusion Blow Molding for 5 gallon PC water bottle
Water bottles of PC 5 gallons (18.9 = 19 liter) are being produced by extrusion blow molding.
Processing temperature for PC is 300ºC.
The general properties can be summarized as follows:
- Excellent physical properties
- Excellent toughness
- Very good heat resistance
- Fair chemical resistance
- Transparent
- Moderate to high price
- Fair processing
Extrusion blow molding is divided into two types
- Continuous
- Discontinuous
Low volume bottles are produced by continuous extrusion blow molding. In this type more two or more pair of molds work in synchronized manners.
Extrusion blow molding for 5 gallons Polycarbonate water bottle, consists of following steps.
- Drying of raw material (Resin)
- Mixing of resin, color and other additives and fillers
- Plastification and melting of material
- Parison forming
- Mold closing
- High pressure cool air through nozzle pin
- Cooling
- Mold open
- Ejection of bottle
- Removal of flash at the bottom and upper part of the bottle.
Complete procedure
First of all resin is dried and then mixed with color and other additives. This material is then transferred to hopper of the extrusion blow molding machine. Extrusion blow machine provides better mixing of color than injection molding a homogenize mixture of molten is formed at the end of extruder. At the end of extruder screen pack and then die head assembly. Two types of dies are used:
- Converging
- Diverging
Molten plastic from die takes the shape of tube. When length of parison is more equal to the length of bottle (actual length is slightly more) blow pin comes in and mold closes. High pressure air from the blow pin pushes all the sides of parison and parison takes the shape of mold (Bottle).
Advantages
- Extrusion blow molding in simple process
- Very good mixing
- Single step
- Larger volume bottles can be produced easily
Disadvantages
- Weight varies bottles to bottle
- Uneven wall thickness
- Lines on the surface of bottle
Difference between Extrusion Blow molding 5 gallon water bottle and Stretch blow molding 5 gallon water bottle
Difference between extrusion blown and stretch blown is seen on the bottom of the bottle. Extrusion blown bottles have flash marks at the bottom while stretch don’t have such mark but only injection point.
Hot Runner and Cold Runner systems for Injection molds
Plastic injection molds are divided into two types on the bases of runner system.
Runner system:
Channel system that leads molten plastic from sprue to mold cavity through gate is called runner system. Following are the two types of runner systems:
- Cold runner system
- Hot runner system also known as runner less
Cold Runner System
Cold runner mold can consist of either 2 or 3 plates. The simplest style is the 2 plate system where the runner carrying the molten plastic, is machined into the mold plates. After the part is molded, both the part and the runner are ejected. In mold with three plates, the runner is machined on a separate plate so the parts are ejected alone.
Advantages and disadvantages of cold runner system
| Advantages of cold runner | Disadvantages of hot runner |
| Less expensive to manufacture | Cycle times are slower |
| Color changes can be made quickly | Potential waste from runners especially if they cannot be reground |
| Lower maintenance costs | |
| Accommodate a wide variety of polymers |
Hot Runner System
The hot runner system first came into use in the 60’s, but did not gain popularity until the 80’s and 90’s when technical advances made them more reliable, and the increases in plastics material prices made them more desirable.
Hot runner system Types
- Insulated hot runner
- Internally heated hot runner
- Externally heated hot runner
Heated Hot Runners
In heated hot runner system runners are heated with heater internally in the manifold or externally but the function is the same to keep the plastic resin in a liquid state within the tool except when it passes through the gate into the mold cavity.
Insulated Hot Runners
In this type runner system is not heated externally but it is insulated with thick layer of insulating media all around the runners.
So in hot runner system, the runner is not ejected with the finished part. Instead it stays in the mold ready to fill the cavity to make the next part. In the hot runner system, the amount of resin used is greatly reduced because there is almost no waste of resin to make the parts.
Advantages and disadvantages of hot runner system
| Advantages of hot runner system | Disadvantages of hot runner system |
| Potentially faster cycle times | More expensive to manufacture |
| Eliminates runners and potential waste | Colors cannot be easily changed |
| No need for robotics or someone to remove runners | Higher maintenance costs and potential downtime |
| Better for high volume production | May not be suited to certain types of engineering plastic resins and thermoplastic resins and sensitive materials |
The main key difference is that in cold runner both part and plastic in runner are ejected, while in hot runner only product is ejected.
Extrusion Blow molding with Parison Programming
Parison
Tube shaped material from the die of extrusion blow molding machine is called Parison.
History of Parison Programming
Parison programing was invented in 1958 by Denes B. Hunkar. Which helped to make extrusion blow molding a more efficient and productive plastics manufacturing process. The invention of parison programming turned a very simple extrusion blow molding process into a scientific process.
Die
Two types of dies are
- Convergent Die
- Divergent Die
Die parts
- Mandrel
- Bushing
Mandrel of die
The round shaped metallic block in die around which molten plastic flows is called mandrel of die. Mandrel may be fixed or moveable.
Working of parison programming
Parison programmer is used with hydraulic powered accumulated die head either with convergent or divergent die. In convergent die the diameter of die decreases from molten plastic entering to opening of die and in divergent it increases from machine side to opening of die. For better controlling die head is divided into portions. Each point is called programming point. The complete die head is divided into approximately 200 programmer points.
Total length of parison is dived into programmer points.
Before 1958 parison was of same wall thickness. But if you want to add handle in the blown plastic product that area must have thick section so for this purpose thickness of all the parison has to increase. Which results weight increase and slow process. To overcome this problem blow molder need a solution and parison programmer provide them the solution.
In parison programing either mandrel or bushing is moveable. Thickness of parison can be controlled by the movement of mandrel or bushing. In convergent die, forward movement of mandrel decreases the gap between mandrel and bushing, hence there is decrease in wall thickness of parison, and same is the result when bushing is moving backward. In divergent die case is opposite.
So the wall thickness according to product dimensions is controlled by movement of mandrel. Mandrel moves back and forth to control the thickness during the extrusion of molten plastic in parison form. Gap between mandrel and bushing is controlled by programing points when hydraulic piston reached a specific point the gap either increase or decrease according to parison programmer instruction installed by operator.
Advantages of Parison programmer
Reduced amount of plastic used
Even wall thickness
Equal weight distribution
Equal cooling
Fast production
Better control on parison
High strength at top bottom and handle
Extrusion Blow Molding (EBM): Operating Procedures
Extrusion blow molding is a processing technique used to manufacture plastic parts that are hollow. To run every plant, machinery and equipment there is an operating procedure for that plant and machine. In extrusion blow molding every industry follow its operating procedure but there are some common steps.
Common steps which are followed by every extrusion blow molders are
- Pre-startup
- Startup
- Production
- Shutdown
Pre-Startup
In pre-startup of extrusion blow molding first of all set-up sheet must be prepare. Collect and check for previous data for the plastic product you want to manufacture. Check for the plastic is it require drying? If drying is required then how much time and at what temperature? Answer of all these question must be there before starting up. Before starting up all the heaters, controllers, gauges, hydraulics and other thing are checked for their proper working. Faulty equipment is replaced before it disturb during actual production. Also check the resin for any contaminations.
Set-up sheet
Set-up sheet may be prepare for every material and every machine. Set-up sheet contains every detail of plastic and machine. Temperature profile and other material and machine setting parameters for that specific material and product.
Start-up
After pre-startup the next step is start up. Temperature of barrel and die is set, when required temperature is gained by all the heater then turn on the machine at low rpm and set the parison according to your product. When everything is according to your set parameters then speed up the machine. If machine was running with any other plastic than you want to process then purging is required. Purge all the material before running new material.
Production
Next to start-up is production. Production must be according to specifications provided to you. During production check dimensions, shape and other details of product also check for any spot or other problem in the final product. If problem is found it must be solved immediately. For example if you are producing a 30 litter jerry can you must check for neck details, weight, parting lines, black marks, and any other defects. Production rate depends on cycle time in extrusion blow molding. Increase in production may be due to faulty auxiliaries eg chiller.
Shutdown
Improper shutdown decreases the life of every machine. Extrusion machine must be always properly shutdown. The proper shutdown procedure is that a purging material is used to remove all the material in the extruder, die, and head. When purging material starts coming out then it is ready for shutdown.
Extrusion Blow Molding: Part Quality and Problem Solving
Extrusion blow molder face many problems daily during the production. If problems are not solve immediately and efficiently then there is decrease in profitand efficiency. To overcome these problems and to run smooth productionanalytical method of problem solving method is used.
Analytical Method of Problem solving
In actual analytical method, one compares all the actual control settings at that timewith setup sheet and check for every setting if there is any change in any settingscorrect it. If all the settings are according to setup sheet then determine where theactual problem is and either problem is continuous are discontinuous. If notcontinuous, determine when the problem is occurs.Problem can be solved by changing in following:
Problem can be solved by changing in following:
- Variables of Plastic Processing
- Machine Control Changes
- Plastic Processing Conditions
- Molded Part Properties
Variables in plastic processing
For solving problem these four variables are changed
- Plastic Temperature
- Plastic pressure
- Plastic Flow Rate
- Plastic Cooling Rate
So to solve the problem changes can be made in any one of these four or combination for example temperature of resin may be different batch to batch. Plastic flow from hopper to barrel or from auto loader may vary. If cram feeder is being used rpm or feeder may vary.
Machine control changes
Machine control that can be changes to end problem are
- Barrel Temperature
- Parison rate
- Accumulator Temperature
- Die head temperature
- Cooling time
- Mold temperatures
- Air pressure
- Air flow rate
These 8 changes can be made in machine controls to remove problems like increase the barrel temperature if machine load is increasing and lower the barrel temperature if plastic starts degrading. Change in any above parameters may take 20 to 40 mints depends on the size of machine. So wait till that change. Change in any parameter may results in change more than one parameter so be careful while changing any parameter.
Plastic processing conditions
Plastic processing conditions that can effect production and product quality are
- Temperature
- Pressure
- Cooling
- Flow rate
These four changes effect such as high temperature outside requires high rate of coolant in the mold reverse is the case in winter.
Extrusion Blow molding Steps
Extrusion blow molding can be divided into three simple steps
- Parison, a tube like shape forming
- Reshaping the parison into a blown part that meet customers specification
- Cooling the part in the mold
Variables controlling the flow of plastic through die head
Gap thickness between mandrel and bushing
Plastic pressure
Land length of die
Viscosity of molten plastic.
Injection Molding Machine (IMM): Basic Functions
Injection molding process is a versatile process. Many changes has been made in injection molding machines and injection molding process. Variety of injection molding machine are available today. Fully manual, semi-automatic, fully automatic injection molding machine are available today. Fully automatic machine are further divided into categories like hydraulic injection molding machines, All-electric injection molding machines, and hybrid Injections molding machines.
The basic function of all injection molding machines are same either it’s manual and fully automated.
Injection molding is a cyclic process. The cycle of injection molding machine include following steps:
- Melting
- Mold closing
- Injection
- Cooling
- Mold opening
- Ejection
Injection molding is a process in which plastic resin/chips are transformed into molded plastic part. Injection molding process starts from feeding plastic into hopper. From hopper plastic goes into the barrel and a rotating screw with flights on it conveys and melts that plastic. Screw on injection molding machine is divided into three sections or zones. 1st section is feeding zone 2nd is called compression zone and 3rd last one is called metering zone. In some new IMMs there is a new mixing zone. Which increases the mixing efficiency of screw. Screw flight depth decreases from feeding zone to metering zone. At the end of metering zone a NRV (Check valve) is used to prevent back flow of molten plastic.
Molten plastic is stored in between nozzle and check valve. Reciprocating screw (Have ability to move back and forth) of injection molding pushes that molten plastic into mold cavities. In mold plastic part are formed and cooled.
Molds of injection molding are different in shape and fabrication material is also different. One side is core and second side cavity.
After the molded part cooling it is ejected.
Some common defects in Injection Molding
Common defects in injection molding process are flash, Short Shot, Gas or burn marks, Lines or streaks and bubbles etc.
Extra material at parting line is called flash. Flash may be due to high injection pressure and high holding pressure. Flash may also occur because of low clamping force.
Short shot means injected plastic is less than required to fill the cavity completely. It may occur due to low injection pressure and may be due to some other reasons like poor air venting in the mold.
Milk (Dairy) Processing
Milk is a fluid secreted by the mammary glands of healthy cows of the bovine species during the usual lactation period by means of complete and regular milking. It is a concentrated food, designed to initially protect the newly born animal by supplying concentrated antibodies to counter disease until the immune system of the young animal is fully functional, and thereafter also to ensure rapid growth until the young are more independent.
Milk is a valuable nutritious food that, if untreated, will spoil within a few days. However, there are a number of preservation techniques that can be used at a small scale to extend its shelf life by several days, weeks or months. Some of these processing methods also produce foods that have different flavors and textures, which can increase the value of the milk when these products are sold.
Milk Processing Divisions
Pasteurized milk, Butter and ghee, Soured milk and yoghurt, Cheese – making, Ice cream production and Dairy confectionery. Other methods of milk processing are making dried milk powder, sterilized milk (Ultrahigh-Temperature or ‘long-life’ milk and bottled sterilized milk), canned (evaporated or condensed) milk, or milk by-products such as casein.
Spoilage, food poisoning and preservation
Milk is not only nutritious for people, but also for bacteria. Because milk is a low acid food, bacteria are able to grow in it and contaminate any products that are made from it. If milk is not properly processed or if it is contaminated after processing, bacteria can change the flavor, texture or color of dairy products, to spoil them and make them unacceptable for sale. Other dangerous bacteria can grow in milk and cause food poisoning. Illnesses such as tuberculosis, brucellosis and typhoid fever can also result from using poor quality milk or milk that is not properly processed.
Methods of processing
There are four main Steps used to process milk:
Cooling fresh milk at 4º C to extend the shelf life by a day or two.
Heating milk to destroy both contaminating micro-organisms and naturally occurring enzymes that change the flavor of milk.
Pasteurization
There are regulations in most countries that specify the time and temperature that milk should be heated to pasteurize it. Most specify that milk should be heated to 63oC for 30 minutes. Higher temperatures and shorter times are used in larger commercial operations but the equipment needed to do this is more expensive
Making the milk acidic to slow down or prevent the growth of spoilage bacteria or food poisoning bacteria (this also changes the milk to a curd).
Reducing the amount of water in milk products to slow down or prevent the growth of bacteria. This may be combined with adding sugar (to make milk confectionery) or salt (in cheese or butter production), both of which also prevent bacteria from growing.
Injection molds for Electrical Appliances
Plastics having very good electrical insulating properties, light weight, weight to strength ratio and antirust properties increases its use in electrical appliances. Electrical parts vary from very simple to very complex single shot to two shot. Both rubber and plastic is used. Aesthetic look is required for domestic. On these bases the molds for electrical appliances are very simple two plate to complex with sliders and inserts. Surface finish is also important in these devices. Printed plastic now a days used with different graphics printed on these device that add a new look to device.
List of electrical appliances:
- Plastic Housing
- Plastic Body
- Plastic Boxes
- Plastic Casings
- Plastic Connector
- Switches and gears
- Plastic Sockets
- Plastic Hubs
- Plastic Buttons
- Plastic Bridges
Mold specifications for electrical Appliances
Electrical appliances molds are specified according to their end use. Injection molds for electrical should have
- Low cycle time
- Even cooling system
- High rate of production
- Corrosion resistant
- Product without any stresses
- Product according to requirements
Designing of mold
Design engineer design the mold with the help of designing tools and software. There are two stages in designing. 1st Product designing and 2nd mold designing. Plastic product is designed in CAD software and then it is converted to CNC machine language by using a CAM software. CAE (computer aided engineering) software like mold flow is used simulate the mold in real like environment. By CAE flow of molten plastic in the mold is simulated, cooling of product and any other defect can be analyzed that can cause a major problem during real run of mold. After this machining of mold starts.
Mold materials
Mold is fabricated by combining different parts together. These different parts are made from different type of materials. Like Base of molds mostly made from P20 pre-hardened tool steel and core and cavity are made from hardened tool steel like 718, NAK80, H13,S45C, 2311, H13, 2344, Starvax 420, 236, AdC3, 2312, 2379, 2316, 2083, 2767 and others S136 have very good surface polishing capabilities.
Plastic materials for electrical Appliances
- HDPE (High Density Polyethylene)
- PP & CoPP (Polypropylene)
- PC (Polycarbonate)
- ABS+PC (Blend)
- PA66 (Polyamide 66)
- PU (Polyurethane)
- PVC (Polyvinylchloride)
- ABS (Acrylonitrile Butadiene Styrene)
- PMMA (Poly Methyl Meth Acrylate)
The most common materials for the shell of electrical appliances are ABS, PP, ABS+PC, PVC, Polycarbonate and blends of these. ABS is the mostly used plastic as it is cheap. PC holds very good mechanical properties but its chemical resistance is not as good.
An Introduction to Injection Compression Molding (ICM)
As early as to 1960s, Japanese injection molding masters began to research on ICM. However, it was not well developed due to the limitations of machines and molds. In the 1980, injection machine and mold technology had a very fast development which is very good for injection compression development. Nowadays, it has become one of precision injection molding processes. The advances in CAE also help the feasibility of this special molding process.
Injection Compression Molding have properties of both injection molding fast, process can be easily automated and compression molding like thin wall and complex geometrical graphics with full details.
Types of Injection Compression Molding
ICM is further divided into following types:
- Short-Shot Compression ICM
- Full-Shot Compression ICM
- Co-Injection Compression ICM
In short-shot compression molds is filled with 90 to 95 percent and in full-shot compression mold is 100 percent filled with material required for the product and then compression occur. Co-injection compression is little bit different from above two discussed in such way that injection and compression occur at the same time with little delay in compression.
Advantages of ICM
Injection compression molding (ICM) aside from reduced material shear and less orientation, offers numerous qualitative advantages for injection-molding parts. ICM also permits are duction in injection pressure, clamping force, and cycle time. Added to this is often an improved hold pressure effect, which minimizes sink marks and warpage.
Advantages of injection compression molding for the process
- Compensates shrinkage by compressing the melt through the clamping movement
- Distributed, uniformly acting holding pressure
- Reduces holding pressure time, shortens cycle times
- Permits over packing of cavity
- Reduces clamping force requirements
- Less orientation and molecule alignment during injection
- Easier and faster mold filling through improved venting
- Less material shear
Advantages of injection compression molding for molded part properties
- Eliminates sink marks with thicker wall sections and at the end of the flow path
- Reduces to warpage susceptibility improves long-time dimensional stability
- Reduces stresses in mats or films in direct back injection for decorative parts
- Reduces fiber degradation in parts made of long-fiber-reinforced thermoplastics (LFTs) and, consequently, improved mechanical part properties
- Improves optical properties in the case of transparent parts.
- There is a trade-off between the numerous advantages and the extra expense for the machine and mold as well as restrictions in terms of part geometry:
- Undercuts or penetrations across the compression direction are problematic
Only components that are of very great depth in the injection direction are very difficult to produce by i
HDPE Bottles/Containers for the Packaging of Milk
High-density polyethylene (HDPE) containers have been used for decades in a great variety of applications. The first major applications of this technology was the rigid packaging of liquid milk and motor oil. Currently the total consumption of HDPE for blow molding containers in USA is almost 1.8 million metric tons, where milk bottles ranged up to a total of 363.000 metric tonsand 36.000 metric tons for other food applications.
Packaging of industrial fluid milk appeared after 1884, when theglass milk bottle was invented by Dr. Hervey D. Thatcher in Potsdam, NY. Glass container was replaced by plastic-coated cardboard, which in turn was substituted by blow molded HDPE bottles, introduced in the market in 1932 and 1964, respectively.
Other containers, such as “pouches” (bags) are also used for fluid milk packaging; nevertheless, plastic bottle is still the most common package in many countries.
HDPE bottles are manufactured by extrusion blow molding. HDPE monolayer container is used. In most cases where additional protection is required, a multilayer container can be coextruded.
Label
The label provides an easy and cheap method to promote a product and allows a continuous change in design in order to keep consumers interest, adding value to package by including information for customers, coupons, recipes, etc.
The type of label provides up to 75% more space for information about brand, nutritional value in multiple languages and larger letter size for impaired and elderly consumers, special promotions and occasional marketing.
Lids
Lids and closure systems are in charge of keeping beverage inside the container. They also maintain product freshness, provide a barrier to dirt, oxygen and moisture, and prevent leakage through openings. Additionally, they can be used for promotions as marketing tools.
Other ideas to promote milk through the lids are:
- The lids can be identified with a particular milk brand in order to make the container more noticeable.
- The lids which include a liner and a tamper evident ring can use their inner part to offer instant prizes.
- The lids can come in different fashionable colors, such as a clear transparent purple or a neon yellow, while the liners can have holographic images.
Benefits of HDPE Plastic Bottles
Recyclable:
HDPE bottles are 100% recyclable so material can be used over and over again
Sustainable:
HDPE offers opportunities to integrate recycled material back into the supply chain
Adaptable:
The only bottle type of plastic that can be used as a monolayer bottle for pasteurized milk, or as a coextruded bottle with barrier layers for UHT or sterilized milk
Easy to use:
The only type of packaging that allows an integrated handle and pouring aperture to enable controlled grip and pour
Safe and secure:
HDPE is safe and secure for milk packaging.
Commercial:
HDPE bottles offer a full range of marketing opportunities, e.g. printing direct onto the material, printing direct onto the sleeve or label.
Innovative:
Ability to push boundaries and achieve new milestones with innovative use of blow moulding equipment
PET Bottles for Milk Packing
Easy to handle and with real weight and safety advantages with regard to susceptibility to breakage, PET bottles offer real benefits to both manufacturers and consumers. French dairy company LSDH is claiming a world first for the launch of the PET bottle for UHT milk using dry decontamination technology. PET bottles have high strength to weight ratio than other plastic materials that are used for the packaging or milk. PET bottles can be used for both types of filling cold and hot. At high temperature filling ordinary plastics began to deform even amorphous PET also but PET have properties that it can be crystalized and crystalized PET can be filled at high temperature.
Acetal Aldehyde (AA) Level
Acetal Aldehyde is present in raw PET granules that do not create any problem or health hazards but if PET if processed at high temperature then AA level increases which causes change in the taste of packed fluid in it.
PET milk bottle advantages:
Significantly lower weight of a milk bottle than in case of other materials such as glass or HDPE (weight of 1L milk PET bottle is only 25g, while weight of 1L HDPE container is 38-40g).
Decontamination of bottles
Packaging of milk is not an easy task as milk and milk products can be destroy, change its odor or color when exposed to light, air or microbes. To overcomer and avoid this situation decontamination process is compulsory for bottles before filling with milk or milk products. Decontamination is done by steam or by new technology hot decontamination by hydrogen peroxide.
No material loss during production
Lower costs due to material saving and manufacturing technology (high efficiency, low power consumption, full automation of the process).
PET milk bottle offers better barrier against oxygen and better protection from odors than HDPE.
Possibility of producing tailor-made bottles with original shapes, which are attractive and aesthetic for customers and create great marketing opportunities.
PET milk bottles can be transparent or colored in different colours including white, which reduces the effect of light on milk.
Smooth, aesthetic finish of a bottle neck, formed during preform injection – no knife cut-off trace or spikes like in a HDPE.
New generation of cap closure dedicated to milk PET bottle that prevents contamination of the product in case of multiple use (repeated opening and closing).
PET milk bottle is extremely lightweight and has a high shock-resistance. It’s convenient for production and distribution.
Transport in several layers is possible – up to six layers with the right bottle design.
Positive environmental profile as PET milk bottle can be easily recycled.
Like glass, PET is a biologically inert material that doesn’t react with beverages or foodstuff and is resistant to attacks by micro-organisms.
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