A. High-continuity production, reducing downtime losses The
"injection-blowing" integrated process of the injection-blow
machine itself reduces downtime for process connection, but modern
equipment further reduces non-production time and improves
equipment utilization (OEE, overall equipment efficiency) through
detail optimization:
• Quick mold change system: Traditional mold change requires manual
removal of mold bolts and calibration positioning (taking 30-60
minutes), while the injection-blow machine is equipped with a
"magnetic/snap-on quick mold change device" - the mold and
equipment are fixed by strong magnetic adsorption or mechanical
snap-on, with "locating pin + laser alignment" (positioning
accuracy ±0.02mm), the mold change time is shortened to 5-10
minutes (for example, switching from the production of 50ml
medicine bottles to 100ml medicine bottles, only the mold cavity
needs to be replaced, and there is no need to re-adjust the core
parameters). For multi-variety, small-batch production (such as
cosmetic bottles, with a daily output of 10,000-20,000 pieces of a
single variety), the mold change downtime can be reduced by more
than 30%. • Automatic feeding and waste material processing
linkage: Raw materials are automatically transported to the hopper
through the "vacuum loader" (can store 2-4 hours of consumption),
and a "material level sensor" is installed in the hopper. When
there is a shortage of materials, an alarm will be automatically
sounded and the spare hopper will be started to replenish materials
(no need for frequent manual feeding); at the same time, a small
amount of waste materials generated during production (such as
bottle mouth residual materials, trial mold waste) will be crushed
by the "online crusher" and directly mixed with new materials
(ratio ≤10%) for reuse, avoiding downtime and cleaning caused by
waste accumulation (traditional downtime is required for 20-30
minutes for cleaning). • Fault self-diagnosis and early warning:
The equipment has a built-in "fault database" (including 500+
common faults, such as hydraulic oil leakage and heating coil
damage), and the status of key components (such as hydraulic system
pressure fluctuations and motor current abnormalities) is monitored
in real time through sensors. For example, if the temperature of a
certain heating coil is continuously lower than the set value
(deviation>5℃), the system will judge it as "heating coil
disconnection", and immediately pop up a fault location diagram
(marking the specific heating coil number) and prompt the
replacement steps, shortening the maintenance time from the
traditional 1-2 hours to within 30 minutes.
B. Deep automation integration to reduce manual dependence The
injection blow molding machine can be seamlessly connected with
upstream and downstream equipment to form a "fully automated
production line", which is especially suitable for scenarios with
high labor costs or high cleanliness requirements (such as
pharmaceutical workshops):
• Fully automatic pickup and palletizing: After blow molding, the
robotic arm (equipped with food-grade silicone suction cups) picks
up the parts from the mold (pickup time ≤ 1 second) and directly
transports them to the "cooling conveyor belt" (the cooling time is
set according to the size of the product, such as about 5-8 seconds
for a 30ml bottle). After cooling, another group of robotic arms
palletizes them in a "stacked" manner (10-20 pieces per layer,
1-1.5 meters high). There is no human contact throughout the
process (to avoid fingerprint contamination or bump deformation).
Only one person is required to monitor a single device, which saves
more than 60% of manpower compared to traditional manual pickup
(requiring 2-3 people). • Cleanroom-adaptive design: For
pharmaceutical packaging (such as infusion bottles and vaccine
bottles), the equipment adopts a "fully enclosed structure" - dust
covers are installed in the barrel and mold area (positive pressure
is maintained inside to prevent external dust from entering), the
hydraulic system uses "food-grade hydraulic oil" (no volatile
pollutants), and all parts in contact with raw materials (screws,
barrels) are "electrolytically polished" (smooth surface without
dead corners, and can be sterilized with high-temperature steam),
meeting GMP cleanroom standards (Class 8 and above). • Production
data traceability: The equipment is equipped with an MES system to
automatically record data such as "raw material batch, molding
temperature, production time, and test results" for each batch of
products (storage period ≥ 3 years). If quality problems are found
later, the batch number can be traced back to the specific
production period and equipment parameters (for example, if the
sealing of a batch of medicine bottles is unqualified, it can be
checked whether the blow molding pressure during that period is
abnormal), meeting the "full traceability" requirements of the
pharmaceutical industry.
C. Adapt to special structural products and expand product forms.
Through mold and process optimization, the injection blow molding
machine can form complex structures that are difficult to achieve
with traditional blow molding to meet customized needs:
• Special-shaped bottle mouth and one-piece molding structure: For
example, the "bottle mouth + pump body base" of the cosmetic press
pump is integrated into one molding - traditional split production
requires injection molding of the pump body first and then welding
it to the bottle body (easy to leak), while the injection blow
molding machine can directly form the bottle mouth thread and pump
body slot (accuracy ±0.05mm) in the blow molding stage, without the
need for secondary assembly, and the sealing performance is
improved by more than 80% (the leakage rate is reduced from 0.5% to
below 0.1%). • Compatible with thin-walled and thick-walled
products: It can produce "thin-walled lightweight" products (such
as 500ml mineral water bottles, with a wall thickness of 0.2-0.3mm)
- through "high-speed blow molding" (blowing pressure 1.5-2MPa,
blowing time 0.5-1 second) to achieve rapid molding; it can also
produce "thick-walled load-bearing" products (such as 5L chemical
barrels, with a wall thickness of 2-3mm) - through "segmented
pressure holding + slow blow molding" (pressure holding time
extended to 5-8 seconds, blow molding pressure 0.8-1.2MPa) to avoid
shrinkage marks in thick-walled parts due to uneven cooling. •
Multi-cavity synchronous molding: For small-sized products (such as
10ml oral liquid bottles), the injection blow molding machine can
be designed with "4-cavity, 8-cavity or even 16-cavity molds", that
is, one-time injection molding + blow molding to produce 4-16
products at the same time (each cavity is independently controlled
to avoid the overall production being affected by the failure of a
certain cavity). Taking an 8-cavity mold as an example, the
single-mold cycle is 15 seconds, and the daily output can reach
8×(3600/15)×24=46080 pieces, which is 8 times more efficient than
single-cavity equipment, and the consistency of each product
(weight deviation ≤1%) is better than multi-machine division of
labor production.
Precision IBM Injection Blow Molding Machine For PE PP Pharmaceutical Bottle
