Mechanical Engineering.

Home

Engineering Mechanics

PLC based control systems

Mechanical Engineering

Electrical Engineering

Pneumatic Training Course

Engineering Vibration

PIC microcontroller books

Programming PIC microcontrollers

Manufacturing of Plastic Bottles

Manufacturing of Plastic Bottles (PET)

Introduction to PET Bottles
Plastic Bottles nowadays is something that is in high
demand, is it mainly because of its durability.
Majority of people around the world use it in a daily
basis. Containing innumerous uses, plastic bottles or

plastic to be specific, must be one of the greatest

discoveries in the recent centuries.

Fig01: Polyethylene terephthalate, otherwise known as PET, is the

most
commonly used plastic nowadays

About Polyethylene terephthalate used for Bottling

Polyethylene terephthalate is not made is not made

in a single process. It is made by the reaction of two
chemicals known as Purified terephthalic acid (PAT)

and
These

ethylene
two

glycol

chemicals

form

(EG).
Polyethylene

terephthalate along with other types of plastic, used

in variety of applications such as engineering, nylon
production,
Below

are

etc.
some

Properties

terephthalate
Density:1.38~1.40g/mm3
Melting Temperature: 254-256C
Crystallinity: >=45%
Glass Temperature: 82C

of

Polyethylene

Fig02: Repeating unit of Polyethylene terephthalate.

PET is a long chained molecule with the repeating unit displayed above, resin, a bluish
white substance, is made from poly condensation of terephthalic acid and ethylene
glycol. Resin manufacturers supply PET in the form of small pellets, each weigh about
0.05 grams.Being transparent, PET can reach a tensile strength of about 1/3~1/2 of
steel's.
The number of PET repeating units per chain, used in the bottle industry to make plastic
bottles

is

about

100

to

155,

usually

labeled

in

terms

of

resin

IV.

Uses of Polyethylene terephthalate

Also known as PET, is a thermoplastic is which is one of the types of plastic
amongst million others. By far the most useful type of plastic, PET bottles are used
mostly in the beverage industry, where the bottles are filled with the particular
beverage and supplied around the globe. It can be water, fresh juice, or any other
beverage. Some of the most common uses would be bottling of mineral water,
edible oil, juice, cosmetics, pharmaceutical, etc.

Main Advantages of PET

Pure PET does not involve, by reacting with the food or beverage which is kept
within the container. Therefore, PET complies with international food contact
regulations.

Lightweight 10 times, lighter than a glass pack, PET bottles, hence, reduces
shipping costs by 30%. If a glass and PET bottle having the same size is
compared in volume it can store, PET will come in first, as its wall is thinner.

Crystal Clear The product looks clean and healthy and in physical good shape.
These attract attention and increases the sales of the products contained within
it.

No Leakage Due to the absence of a weld line in the bottom the PET bottles
leakage does not occur.

Design Flexibility Can be designed in all shapes and sizes, designs and colors.

Recyclable As it is one single material, PET bottles can be washed and

crushed into flakes and remolded into shape. It has other uses after it is recycled
such as for strapping, making carpets, etc.

Production of PET bottles

Usually PET bottles are manufactured using 2 different methods.
These are :1. One-Step "hot perform" method.
2. Two-Step "cold perform" method.

Step-one "hot perform" method

This method is just one step, from PET granule to finished bottles, all the processors
are done in one integrated machine. That is from the injection mold of the preform to the
removal of the preform from the injection cavity, and to stretch blow the preform to a
bottle all in one machine, while the temperature remain constantly high for the whole
process as injection molding and blow molding, the material should in an elastic form.
This method saves a lot of energy as the material only has to be heated only once, that
is when it is injected to the cavity to produce the preform. The One-Step method is
commonly used in small or medium PET production companies.

Fig03: One-Step hot perform method Integrated

Machine.

Step-two"cold perform" method

This method has 2 distinct machines to perform the injecting and blow moldings. The
preform is injected into shape on the first machine, and then the preform is reheated as
the it isn't brought directly to the blow molding machine and blown on the second
machine. This method is not very efficient as the heat lost is considered as a loss of
energy. But this machines are fully automated.This method is used in most medium to
large scale PET production companies.This machine is 200% more efficient than the
one-step machine.

Fig04: Two-Step cold perform method, Fully automated machine.

Usually the Two-Step Method is used in production of PET bottles.

Driying and Dehumidifying of PET

PET is a type of plastic that absorbs moisture with an average water content of 0.05%.
To increase the quality of the preform in transparency and physical performance the
PET is dried to reduce the water content of the PET resin to less than or equal to
0.005%. The following drying methods are used.

Oven Dry The drying is done at a temperature of 110C for a maximum of 8

hours after which PET will start to fail. The trays with PET inserted into the oven
are about 50mm thick. The oven isn't connected to the injection machine ant the
dried PET is moved manually.

Hopper dryer The widely used method of drying PET as it very economicaland
works along with an autoloader, therefore the process is continuous and
automatic.

Fig5: A hopper dryer used to dry PET granules.

A Dehumidifier Similar to the hopper dryer this also words together with an
autoloader, but it is the most efficient method in drying. The PET dries in at a
temperature of about -32C, thereby increasing the durability and the final finish
of the PET bottle.

Fig06:A Dehumidfier used to dry PET granules.

The Optimum drying temperature would be about 150~170C. The best duration for
drying the PET would be about 4 hours. The drying time should not surpass 7~8 as will
deteriorate the PET.

Injection Molding of the PET Preform

Fig7: An Injection molding machine with essential equipment attached.

The above picture shows an injection molding machine with the autoloader and dryer
other essential equipment needed in the process.

Fig8: Schematic illustration of the injection molding

process.

The process is simple, the heated PET which is in the molten form is injected into the
injection chamber (2),by the rotation of screw barrel (1) within the machine, until the
chamber is full.

Once the chamber is full, the screw pushed forward (3) to fill the injection cavity with
molten plastic through the nozzle into the mold.
The temperature within the injection molding machine are different, at the rear end of
the machine the temperature should be around 275C, at the middle of the machine
about 282C, at the nozzle about 280C. And at the runner the temperature should be
around 270C for the bottle formed to have optimum specifications. (These temperature
may vary a little depending on the design of the mold)

Fig9: PET Preform Mold

Fig10: Preform being Heated

Subsequently the molten plastic within the mold,called the preform, should be cooled.
The cooling water used to cool the perform should be in the temperature range between
15~20C, the pressure also has to be controlled, therefore a water chiller is used. The
pressure should be kept around 500,000 Pa or 5Bar.

The PET preform is ejected (4) from the mold. Now the preformis reheated to the
temperature until it is suitable for the blowing process.

Fig11: A Typical Water Chiller.PET Preforms

Fig12:PET Preforms

Stretch Blow Molding of the PET Preform to Container

The Following process in production of PET is a type of Blow molding called Stretch
Blow molding, as air is blown into the preheated PET Preform.

The other types of Blow molding are:-

1. Extrusion Blow molding

Fig13: Extrusion Blow molding Process.

2. Injection Blow molding

Fig14:Injection Blow molding Process.

Blow molding is a process of forming hollow object by blowing a blowing into

thermoplastic, in this case PET Preform, which is heated and in its maximum elastic
condition. The blow molding process used in production of PET Bottles is Stretch Blow
Molding.
This process is also called Biaxial orientation blow molding as the preform is first
stretched by the blowing device, for the reason that the molecules of the preheated
preform is aligned in one direction and all parallel to each other, then blown in rightangles to the direction of the molecules being aligned.
The theory behind the how this works is, when the PET is heated the long-chained
molecules can loosen then as an alternative to breaking, they orient when stretching.
Therefore,this (stretch blowing)is also called biaxial orientation as it deals with two axes
stretching.
This stretching increases the strength of the material because instead of the molecules
in the material act separately, they act as one whole unit.
The following characteristics are improved or increased as a result of this stretching the
PET Preform before blowing into it.

Tensile Strength

Impact Strength

Barrier

Chemical Resistance

The ideal temperature for orientation for PET is 105C.

The compressed air () blown into the PET Preform is first cleanedthrough an air purifier
(). The air must be cleaned since air contaings moisture and oil, which will directly affect
the quality of the bottle. The PET preform is mounted on to the blowing machine (). After
purifying, the air is blown into the preheated PET preform using a blower on to the mold
().

The thickness of the Stetched blown bottels are 0.25~0.38mm. This thickness is
suffiecient as the orientation will increase the products' quality.

Possible Defects while production of PET Bottles

One of the Major defects in the production of PET Bottles is the production of
Acetaldehyde.
This compound also called as AA, is the taste of an acidic taste in most citrus fruits. This
taste in the bottle can ruin the taste of the drinks, especially if its water as the taste of
pure water isn't strong enough to disguise the taste of AA, unlike the sweet flavors. If the
presence of the AA is noticed the quality of the product literally, goes down the drain.
AA is produced along with the PET when the temperature of the material is higher than
260C, this temperature is reached inside the injection molding of the preforms,
therefore is the process is not maintained correctly, AA is produced along with the PET
preform.
Decreasing the melt temperature and the residence time and help reduce the
production of AA.
Other forms of defects are briefly mentioned below.

OH- or COOH- end groups doesn't becomes non-reactive.

Amount of poly-functional macromolecules increases.

Hydroxide and peroxide groups build up at the surface of the PET and etc.

Fig16:The Total PET Bottle Production Process

Manufacturing Costs
Process: PET bottles manufacturing process involves two basic stages of pre-form
manufacturing and Bottle Stretch Blow Moulding. In a one-step process, the PET bottles
are made directly from the resin. Both the pre-form manufacturing and stretch blow
moulding is performed on a single line. (see Table-I)
Machinery
Injection Molding Machine
Blow Molding Machine
Compressor
Cooling Tower
Chiller Unit
Lather 8ft, refurnished
Lathe 5.5ft
Pillar Drill 26 inches with pump
Facer
Shaper

Number
1
2
1
1
1
1
1
1
1
1

Indian Rupee
750000
800000
150000
150000
80000
110000
72000
50000
150000
125000

(These are indicative estimates, therefore, the intended investor must make his own
calculations by market survey). Injection moulding machines of two different sizes are
required as the proposed production mix depends upon different sizes. The usual
machinery delivery time is 15-20 days, while import can take up to 4 months' time,
depending upon the availability. The stretch blow moulding machines are being
manufactured locally. Lathe machines, pillar drill, facer and shaper, required for the
workshop, are also manufactured locally. (see Table-II)
Human Resource
CEO

Number
1

Annual Salary
360000

Production Manager
Accountant
Injection Machine Operators
Blow Machine Operators
Pre-form Handler
Helpers
Guards

1
1
2
2
1
4
3

192000
96000
168000
168,000
30,000
120,000
108,000

Land and building: An area of about 5,000 sq. ft would be required for the project.
Management building 100, production Area 1,800, raw material store 300, finished
goods store 500, loading area 700, workshop area 850, cooling tower/chiller 700 sq. ft.
Key assumptions: 288 days p.a. Annual production capacity 5,840,640 bottles, capacity
utilisation (1st Year) 40 per cent, capacity growth rate (yearly) 2 per cent, maximum
capacity utilisation 95 per cent, first year production utilisation 2,304,288 bottles. (see
Table-III)

Others
Growth Rate
Electricity
10%
Wages
10%
Office equipment
10%
Machine maintenance
5%
Initial approximate cost/Kg (Rs) 81, Sales Tax 15 per cent, freight cost per kg 1.22.
Weighted average cost of raw material per bottle may come to Rs2.81. Other heads
include administrative costs, promotional expenses, insurance, electricity and taxes.
(see Table-IV)
Other
Building & infrastructure
Machinery & Equipment
Furniture & Fixtures
Project life
Debt: Equity Ratio
Interest rate on long term debt
Discount rate for calculation of NPV

Depletion Rate
5%
10%
10%
10 years
50:50
16%
20%

Raw Material Consumption per Bottle And the final costs. (see Table-V)
Size

Weigh
t

Cost (Indian Rupees) per 100

Bottles

Cost (Sterling Pounds) per 100

Botttles

0.5
Liter
15 Liter
5 Liter

15.5

146

1.98

33.3
74.7

313
702

4.25
9.53

Weighted average cost of raw material per 100 bottles comes to about 3.82. While
average sale price per 100 bottles may be 9.21.
(Investment Opportunities: Packaging medium.
Newer Post Older Post Home

CONTENTS

1. Industrial application of pneumatics

Basic Pneumatic Training Course

Component of a pneumatic system

Compressed air preparation

Electro Pneumatics

Engine block manufacturing process

Fans and Blower design

Industrial Application of Pneumatics

Internal Combustion Engine Cycles of Operation

Manufacturing of Integrated Circuits

Manufacturing of Plastic Bottles

Manufacturing of brake disc

Pneumatic Cylinders

Pneumatic complete lecture note

Pneumatic tutorial problems

Programing PIC microcontrollers

Rotational molding process

Sheet Metal Work using SolidWorks

Solar Dryer

SolidWorks
Simple template. Powered by Blogger.