Category Archives:
Social Media Archives - Page 3 of 5 - Sadhi Machinery Plastic Product

For making products made from high-density polyethylene (HDPE), polypropylene (PP), polyethylene terephthalate (PET) and polyvinyl chloride (PVC) thee extrusion blow molding machines are used. With these materials, you can make a wide range of products like plastic bottles, fuel tanks, toys, and many more.

In the process, the extrusion blow molding machine molten resin extrudes into a parison from cylindrical shape. The two halves of the mold close around it. At both the top and bottom portion of the mold, the cylindrical shape of the mold pinches tight when the tube is in the center.

In the mold, the pressurized air through a needle and is inserted in the tube and this expansion to the mold shape. After cooling down the resin, it becomes solid and mold is open and after finishing the product is ready. A manufacturer can add colorants, adhesive or barrier layers with the resin.

SMP is a trusted extrusion blow molding machine manufacturer in India that provides excellent quality machines. There are slight differences in the blow molding machine design and it depends on extrusion blow molding machines.

These are

Material Hopper

Extruder

Hydraulic Cylinder

Accumulator head

Blow pin

Closing clamp

Blow Mold

Mold platen and clamping unit

For the operations of the machine, all the parts must in perfect condition. The head of an extrusion blow molding machine is very important.

How to Clean the Head?

First, for the cleaning process of heads of extrusion blow molding machine, disconnect or shut off the auxiliary feeding equipment. For better production and precision product the parison head must be clean.

Some polymers degrade during the molding process when it runs at high temperatures. Now if the head is not clean regularly this degraded material accumulates in the head. And if this happens it creates stripes on the surface and the product doesn’t look good aesthetically.

Now before removing the head from the machine use the electric heater to increase the temperature up to require the temperature to melt the plastic. After that remove and open the head and with the copper-beryllium or copper for collecting the melted resin. With the high-pressure air combined with brass cotton for eliminating the remaining material. Also, for removing melted plastic, the anti-sticking agent can be used.

After completion of cleanup, you can start the extrusion blow moulding machine. In the cleaning process try to clean maximum contamination. If this takes more time, you can install a new screen pack and make adjustments to clean the head.

As in the current time, many of us want a quote for the final product. If you are the buyer of the product or finished goods for your company, it’s your responsibility to get products into the warehouse. It is very difficult to well for technical issues in designing engineering, supply chain, material science, and packaging.

It is not just easy to tell the specifications and choose two or three companies and give a contract on less quotations. You aspect the good customer service and expect quality and fast turnaround. Many manufacturers send the quotation for the requested quantity.

Let’s see the next step. Control over the process which allows more creativity for both you and your vendor. If you share this with the manufacturing team, they could help to lower the cost and adjust the price of the client expectation.

According to manufacturers, the design can determine 80% of the total product cost. It is very hard to remove costs after the design is completed.

A less relevant but very important discussion is what is the final price for the end-user. Manufacturing is based on the lowest cost. There are many examples of quality over-engineering and aesthetic design was under consideration. Spending too much time on saving a penny does not help to increase the sales or profit and consider the important characteristics.

The aesthetic design is very important for most of the products. For better design, the production cost is overlooked which increases the final cost. The higher cost reduces the sell. When the selling price and other costs are associated, this will be avoided to add creativity.

After designing the phase, design by reducing parts matches the cost. When any product is developed it tends to be higher quality.

If there is proper time available for planning, development and production can make the manufacturing process easier. Changing in order is more expensive for you and the supplier. Plan your product inventory requirements and also calculate the warehousing and cashflow for price reductions. For many buyers, finance and warehousing are not an issue and told to lower to inventory and increase the turnover, but the lack of flexibility is the reason for the higher product cost. The risk of product obsolescence is an issue but this is not the problem of suppliers but it increases the cost. Planning and adequate time can reduce product cost.

These are the few important information. The most important thing is that your product needs a stronger partner for legitimate work which saves your money and ready your product on time. The below information will help with this:

Manufacturers have to spend money on finding new customers. If they find that you are long term recurring customers, they can lower the price as they have longer production. This is the biggest benefit for manufacturers as they can manage machine purchases and maintain their efficiency which is reduces financing risk and other associated costs. Changing manufacturers can increase their costs. Feel free to ask for lower prices for more production stability.

Management of people requires more money. Having the optimum number of full paid employees to do the job instead of having part-time and contract employees saves money. Tell your capacity of handing the business which helpful for cost-cutting.

Order more work to a single vendor and let them consider in price. Now contract for the price so that they don’t raise the margin means you only have to pay for material changes.

Help your manufacturers in materials by guaranteed volume and the pre-paying portion of materials cost. If the cost of the material is less, the larger materials contracts can lower the manufacturing cost without the risk they will have for the wrong materials in stock. If the manufacturers have extra space for storage can beneficial for large quantity material purchase.

Do not switch to the lower cost vendor when the product development is completed. The new vendor does not understand the production procedure as the older ones. If there is add or change the vendor directly affects the product and increases the chances for error and customer returns. Manufacturers are also comfortable with the machine and understand the machine both internally and externally. Which may reduce the chances of glitches in production and increase production.

To understand the pricing strategy is very important. The difference in pennies may affect the margin but if your overall marketing strategy is on the mark, the customers don’t have any buying problems. Every product or industry has a low-cost leader and most companies have a poor pricing strategy. Many manufacturers have developed new methods for packaging, design and some specialized service with having small cost difference. If the product has quality, service, image, and costs the customer chooses it first. Your efficient partner can help in doing this.

As of today, we think that modern-day plastic polymers are made in the laboratory. But in reality, there are natural materials found thousands of years ago. There are Mesoamericans who used natural rubber into balls and other objects in 1600 BC. The use of adhesives, coatings, and fillers can be found in the Old Testament of the Bible.

Polymers have molecules with a high number of repeating molecules called monomers and they are formed in a sequential chain. There are also naturally occurring and synthetic polymers are starches, latex, cellulose, and proteins.

These materials have long molecules that allow constructing other materials like fibers, films, adhesives, resistant paints and tough but light solids that are transformed for the modern world.

The Ebonite or hard rubber was first discovered in the early 1800s. It was the first thermosetting material. Thermosetting is a resin pre-polymer which is in a soft or viscous state that is changed into the polymer in a curing process. This curing process is completed by the action of heat or radiation under pressure which is called Thermoset.

In the year 1839, Charles Goodyear invented vulcanized rubber and Eduard Simon discovered polystyrene. Simon was a German apothecary.

Charles Goodyear joined the Roxbury India Rubber Company who is the first American rubber manufacturer in 1834. Here he was trying to sell a new valve that he devised for rubber life preservers. The company was unable to do business as there racks full of rubber goods which are melted into a big mess foul-smelling glue because of hot and dry weather. And customers returning thousands of melted rubber products. People started using the new waterproof gum from Brazil. When Goodyear came to Philadelphia was captured by Debtors in the prison where he started the rubber experiments.

When he came out of jail, continued the experiments. He made new shoes but in the summer the shoes turned into paste. He continuing the experiments and he mixed sulfur with the rubber and it is accidentally it is thrown to the hot stove. It turned into a waterproof rubber and hardened also. He had made different products with the experiments. Which are the first and most versatile of modern plastics.

In the year 1850 at the Exhibition of London, Alexander Parkes find that solid residue was left when photographic solvent evaporated. This residue was a hard, elastic and waterproof substance. After some time he patented the process of waterproofing of woven fabrics.

This same process was also discovered by Hyatt brothers and after some legal battles it is known as similar product cellulose. Today it is known as cellulose nitrate. The first-time the word plastic was used in 1925. After sometimes the German chemist comes with information that these substances are made up of 10,000 or more atom. He also studied a polymeric structure of rubber which has repeated monomers. He also receives a noble prize for his excellent work.

The research is continuing in the first half of the twentieth century. Chemists found that many natural resins and fibers were polymers. The first synthetic plastic was Bakelite which was invented by Leo Baekeland in 1907 his company producing the laminating varnish, molding material, and cast resin. The first products were motor distributor rotors, radios, and Ericsson Telephone. In the year 1940 and 1950s, the Bakelite replaced materials like cast iron and tin to make toys. The Bakelite was more durable, didn’t scratch easily and can manufacture in many colors.

In the first half of the twentieth century, the 15 new classes of polymers were synthesized. There is a range of materials developed like natural polymers, modified natural polymers, thermosetting plastics, and thermoplastics. These materials have unique properties like wide temperature usages. The materials like chemical and light-resistant. The materials are strong, tough and low cost compared to other materials.

With this beginning, today there are over 310 million tons of plastics are used annually and continue growing about 5 percent per year.

The polyethylene was developed by Reginald Gibson and Eric Fawcett in 1933. It was used as low-density resin (LDPE) by 1935. The high-density polyethylene (HDPE) was invented in 1953. There are about 25 processes are used for making other PE products. It is the second most used resin. The resin is used to make the plastic film, milk jugs, sandwich bags, cling wrap, pipes, and insulation for electric cables.

The PVC (Polyvinyl Chloride) was first commercially used in the 1920s. The PVC has a different chemical structure and has chlorine, carbon, and hydrogen. The white powder needs a blend of other products to make different products. It is used in piping, medical devices, shutters doors and upholstery, and other industrial applications.

The polystyrene was produced in the 1930s by BASF German company. The polystyrene cups are well known and their modified form is also an excellent insulator for homes and industries. It is also used in TVs and other electronic items.

The PET was discovered in 1941 and today we recognize this polyester film in many forms of bottles that are clear and resist Ultra Violet light. It is also transparent, lightweight and resistance to carbon dioxide permeation.

The polypropylene was discovered by Giulio Natta in 1954 and commercial production started in 1957. This is the most widely used plastic in the world. It is because it has low cost and versatility. It is also thermoformed, blown film blow-molded, injection-molded and extruded into and also a wide range of products like stackable crates for storage and shipping, small, thin-walled containers (yogurt, margarine tubs, food trays), glass replacement, window frames, water pipes and household goods like bowls, combs, toasters, hairdryers and film wrapping for clothing and many other applications.

Most plastics need additives to make various products. It may be the most expensive component of the product and the range makes formulating polymers. The materials forms and additives can create a huge variety of products.

There are many benefits of plastics like lightweight, sterile and easy to manufacture. It has a strength-to-weight ratio which helpful for car manufacturers to increase the mileage. The stronger, lighter packaging bottles are very convenient and save millions of dollars in transportation.

The plastic comes at a price. The durability of the plastic makes it long-lasting. It is not easily degraded in a natural environment which is a risk for nature. The future of plastic is very bright but the industry has to find the solution for recycling.

Every plastic part requires a different manufacturing process and it is different from every product. The injection molding is used to manufacture solid components and on the other side, the blow molding is used to make plastic products with hollow areas like bottles and containers.

The injection stretch blow moulding has the process of injection moulding and blow moulding processes. First, the plastic is moulded into a solid preform to create a threaded bottleneck. After the preform is cooled down it fed into a stretch blow mould machine. After that, the preform is reheated with an infrared heater and blown into a plastic bottle with compressed air.

The Injection and Blow moulding are two core processes for plastic manufacturing. The products made with these processes are widely used in industries like automotive, foodservice packaging, electronics, medical devices, irrigation, dental, firearms, energy, and environmental industries.

For a better understanding of different manufacturing methods, we have provided information about the main types of injection and blow moulding methods used by plastics manufacturers.

Injection Moulding Process

The injection moulding is used for the manufacturing of higher volume quantities of plastic products ranging in size from large components to small components where micro-precision is required.

There are many other types of manufacturing methods like thermoplastic injection molding, over-molding, insert molding, cold runner molding, and hot runner molding.

Thermoplastic Injection Moulding

For the thermoplastic injection molding, the thermoplastic polymer is used and it changes to a liquid state when it is heated. The thermoset plastics are cool down into permanent solid. The thermoplastics can be remitted to the liquid after cooling into a solid.

Over molding

Overmolding or two-shot molding is a process that covers an injection mould over another substance like metal to improve the performance or durability of the product. The rubber-like compound name thermoplastic elastomer (TPE) is widely used for over mould material. The example f TPE in overmold application is the handle grips on a toothbrush. Overmolds can also be used to seal the products with parts made from several injection molds.

Insert Molding

Like overmolding the insert molding is an injection moulding process that has two or more components into a single finished product. In the insert injection, a component is inserting into the injection mold cavity and plastic material is filled around the insert. The inserts can add strength to the product and eliminate the need for additional parts to reduce the product weight.

Cold Runner Injection Molding

The cold runner molds use a sprue o fill the runners that inject plastic resin into the mould cavity. In the two plate molds, the runner system and parts are attached, and the ejection system may be used to separate the pair from the mould. This cold runner can reduce the waste by recycling and regrinding the material but it is also increasing the total cycle time. The cold runner systems can be used for a wide variety of polymers and also allow for easy color changes.

Hot Runner Molds

In the hot runner mould the material is heated and the plastic resin is sent to the material through a gate to fill the mold cavity. The hot runner molds are heated externally and internally. The externally heated molds can be used with a polymer that is less sensitive to thermal variations and internally heated hot runner molds are for better control of material flow.

The hot runner moulding does not require the runners the potential waste materials are reduced and the recycling and regrind the process of virgin plastic does not impact the total run cycle time.

Blow Molding Process

In the blow moulding process, the raw plastic material is shaped into a hollow tube with one open end called a parison. The parison is pressed into a cooled metal mold and compressed air is forced into the parison. When the formed plastic cools down and hardens the metal mold opens and expels the product.

There are mainly three types of blow molding processes.

1. Injection Blow Molding

In the injection blow molding, a blow or core rod is used in the process. First the parison is injected into a split mold cavity around the rod. The parison is formed looks similar to a test tube. The core rod transfers the parison to the blow mold machine where the forced air creates the final shape. After that, the rod then transfers and extrudes the finished product from the machine.

2. Extrusion Blow Molding

The extrusion blow molding can be continuous or intermittent. In the continuous extrusion blow molding, a parison will constantly be fed into the mold and each form will be cut off with a blade as it forms.  In this intermittent extrusion blow molding expels each new plastic from the metal mold when it is cooled and the parison is fed into the mold only after the preceding parison is expelled.

The extrusion blow molds are less expensive than injection blow molds and also manufacture in a shorter time. It is suitable for smaller manufacturing. The advantage of this machine is it is cost saving on tools and shorter production. The disadvantages of this process have lesser control of wall thickness and have a greater amount of scrap material.

3. Injection Stretch Blow Moulding

The Injection stretch blow molding process is a combination of injection molding and blow molding. First, the plastic is molded into a solid perform to create a threaded bottleneck.

After the preform is cool down it is fed into a stretch blow mold machine. After that, the preform is reheated using an infrared heater and blown into a plastic bottle with forced compressed air.

Plastic bottle making industry is growing day by day as it is used because of its convenience for customers. The blow moulding is the primary manufacturing process for manufacturing plastic bottles.

It is one of the best manufacturing processes for plastic containers via blow molding. In the blow molding process, the plastic is formed via injection, extrusion or stretching the material. The process is starting with the melting of polythene, polypropylene, PVC and other plastics before molding them into the mold and compressed air is blown.

The blow molding process is comparably simple as in the process the granular plastic is feed into storage containers with large motorized threads that rotate and compartmentalize the granules through the heated section. This compartment melts the granules in the heated section. The granules are melts into a liquid and transferred to the mold. In the next step, the air is blown into a mold and inflates the material to the shape of the mould. In the end, the mould is cool down and eject the ready product.

Blow molding is a very interesting process and like all other manufacturing processes, it had risk. The blow molding machines have to satisfy the GMP and OSHA requirements and other universal standards for sealing, bottleneck and thread design. The blow moulding machines are very efficient with production and speed and also it can process materials like EVA, PE, PETG, PP, PS, SAN for electronic devices to manufacture different shapes.

Every process step of blow molding is important. It is important to take care of some products that are sold as airtight, childproof packaging, etc. It is very crucial that blow moulding machines are safe but the operators should have to follow the safety rules.

As we have experienced in pharmaceuticals, food, automotive and other industries require special manufacturing applications.

 The well-maintained machinery is important for continuous manufacturing.

The micro-molding blow technology is unique as it is used to manufacture small applications like medicine bottles and other plastic containers. SMP is a leading blow moulding machine provider in India.

There are new scientific testing conducted that shows the PET and HDPE which has a total of 97 percent of all bottles in the North American bottle market can be recycled and reused as new bottles for at least ten times. The first successful experiment was carried by an ESE World B.V in Europe. The next recycling is done in controlled circumstances and controlled by scientists for degradation.

As per the product, the average service life of the product is 10 to 20 years. This means with sustainable production the same recycled plastic has a life of 100 to 200 years.

The company having 30 years of experience in plastic recycling get success in making of cleaning process and additive to make new resin with the same quality of virgin material. On the other side metal and glass can be recycled many times. The increasing life of plastic resin changes the long-term impact of plastic litter.

This issue is continually growing and low recycling rates have to worries. Many consumers are complaining about low recycling rates but the reality is in 2016 there re 1112 million pounds of HDPE waste is collected which is one-third of the possible recovery rate. And it is dropped by 1.1 percent from 2014.

According to the Association of Plastic Recyclers (APR) and American Chemistry Council maximum consumers are unaware of important usefulness, demand and value of recycled plastics.

The plastic bottle recycling rates are highly competitive with aluminum cans. The aluminum cans yield for $0.25 to $0.35 per pound for those who pick them up and collect or take them to the recycling center. For the PET water bottle, it is $0.50 – $0.53 which is roughly double the price for clear, clean PET bottles. And a dime for HDPE.

The solution to this situation is single-use packaging solutions. Governments didn’t come with proper solution. Places like California where some of the plastic bags are banned but the heavier ones are available. Purpose of this is to people reuse those bags which they bought. Some cities find the restaurant for using straws and make the use of straw illegal.

The ban on the manufacturing of plastic containers would stop being made. Consumers are unaware of the risk of using glass breaking i.e shampoo, weight and difficulty of opening tin cans. The shipping cost of glass is higher than the plastic which increases the food prices in retail. Plastic has already proved its benefits.