5.

1 INTRODUCTION
 Blow molding is a process for producing hollow
objects, primarily from thermoplastic materials.

 Bottles and packaging are the primary applications of

blow molded parts.
5.1.1 Plastic Process
 To visualize the blow molding process, think of an
inflatable plastic tube that is closed on both ends
except at one point. If air enters at this point, the tube
will expand, causing the walls of the tube to become
thinner. It is much like blowing up a balloon.

 FIGURE 5.1(Page 305) Inflating an expandable tube.

 The blow molding process begins with a hot, soft
plastic tube called a parison or preform. The parison is
placed between two halves of a mold that has one or
more hollow cavities (Figure 5.2). The mold halves are
then clamped together. Air is blown into the parison,
expanding it against the inside walls of the mold to
form a hollow plastic part in the shape of the cavity.
The mold is cooled, usually with water, and the hot
plastic cools by contact with the mold. Once the part
has cooled, the mold opens and the part is ejected.

 FIGURE 5.2(Page 305) Basic blow molding process.

5.1.2 Brief History of Blow Molding
 TABLE 5.1(Page 307) Key Blow Molding Industry
Events

5.1.3 Typical Blow Molding Markets and Product

Applications
 Bottles are the primary application of blow-molded
plastic parts; however, the blow molding industry also
makes products used in the aircraft, automotive,
building and construction, electronics, furniture, lawn
and garden, medical, and recreation fields.
 Applications include balls, toys, bellows, and car
bumpers (fenders). Many of the bottles and jars are used
in the food industry to package both solid and liquid
products, such as plastic containers for salt and sauces ,
and most food-packaging containers are blow molded.

FIGURE 5.3 (a)

Assorted industrial
and consumer
blow-molded parts;
(b) intricate
blowmolded
case; (c) aerobic
step; (d) dock
floates, foam filled
for buoyancy.
5.1.4 Blow Molding Materials
5.1.4.1 Materials Used
 Thermoplastic materials are often suitable for many applications
without extensive material or component modification, but in other
cases they are not suitable. One reason is that many plastics are
permeable; that is, a liquid product or part of the product can
migrate through the walls of the container, or something from the
environment, such as oxygen, can enter the container through the
plastic walls. For a given plastic material, there are several ways of
overcoming this problem. They include (1)increasing the product
thickness; (2)coating the product with an impermeable material
such as glass, cross-linked PE, or more commonly, polyvinylidiene
chloride (PVDC); (3)incorporation of a platelike filler (e.g., glass
flake); (4)and using a combination of plastic materials. Such
combinations, in which one parison is surrounded by another, are
usually produced by co-extrusion. Orientation (stretching the
parison) also yields improvements.
5.1.4.2 Chemical End Use and Physical and Processing
Requirements
 HDPE is impervious (unaffected by, or resistant) to
water, water vapor, inorganic chemicals, and inorganic
materials in aqueous (water-based) media, especially
at the ambient temperatures normally encountered
during storage and transport.

 Its high moisture resistance makes HDPE an ideal

container material, keeping moisture out as well as in.
However, with organic chemicals and fluids, HDPE
must be used more selectively.
 For hydrocarbon fluids, oils, and solvents such as those
listed below, absorption and permeation through
HDPE become very important factors.

 Most of these compounds are flammable and would

not normally be contained in HDPE containers
without special consideration. Their use as an
ingredient in any product being considered for
packaging or storage in HDPE containers requires
proper testing to determine whether or not excessive
permeation and absorption will occur.
5.2 STAGES AND TYPES OF
BLOW MOLDING
5.2.1 Stages of the Blow Molding Process
 1. Plasticizing (melting) the resin
 2. Production of the parison (extrusion) or preform
(injection)
 3. Inflation of the parison or preform followed by cooling
in the mold (This step takes the most time and controls
the machine cycle.)
 4. Ejection of the part from the mold
 5. Trimming or finishing the part (the trim step is
frequently performed while the other four steps are
cycling)
 It should be noted that when several pieces are made at
one time in multiple molds on one machine, the first
four steps may overlap.
5.2.2 Types of Blow Molding

 1)Extrusion
 2)Injection
 3)Stretch

Figure 5.5-page 314 describes these types and subtypes.

 1)Continuous

2)Intermittent
(Accumulator)
Extrusion
Co-extrusion
1)Suction
Three-
Dimensional 2)Vertical
Extrusion
Blow manipulation
Molding
Injection 1)injection station
3)Horizontal
2)blow station
manipulation
3)ejection station

1)Heating a molded
and cooled preform
Stretch 2)Closing blowing mold
3)Stretching
5.2.3 Extrusion Blow Molding

 There are two basic types of extrusion blow molding:

 1) Continuous Blow Molding

 2) Intermittent (Accumulator) Method
5.2.3.1 Continuous Blow Molding
 In the continuous method, the parison is extruded
continuously from a head or die unit. The extruder
produces an endless parison.
 In one variation of the continuous method, a shuttle
press carries one or more molds.
 As soon as the mold closes, it moves away and an open
mold moves into place as the parison or parisons
continue to be extruded.
 When the mold closes, air is blown into the parison.
 Once the parison has expanded, air pressure holds it
against the mold as the part(s) cool.
5.2.3.2 Intermittent (Accumulator) Method
 In this method, the extruder
runs continuously.

 A chamber, called an
accumulator, accumulates a
substantial volume of well-
plasticized melt that is delivered
by the extruder.

 Once a plunger or ram forces

the melt out through the die
head to form the parison
(Figure 5.6).
 A benefit of the intermittent or accumulator method is that it allows
the delivery rate of hot plastic from the die head to be independent
of the delivery rate of the extruder.
 Accumulator capacity determines the maximum size of large blown
parts. A large accumulator may hold enough plastic melt to make a
parison for a 150-lb (68-kg) part.

 The advantages of an accumulator are:

1)It holds a large volume of melt for large items requiring very long
molding and cooling cycles.
2) It permits high production rates.
3)It permits the fast extrusion of large parisons and consequently a
short suspension time for the parison, allowing comparatively little
sag and better control of wall thickness.
4)It provides more uniform shot size (weight of plastic), which
minimizes waste.
5)It decreases idle mold time to a minimum.
5.2.3.3 Co-extrusion Blow Molding
 Co-extrusion refers to the technology used to make
products that contain multiple layers in their wall
structures. Such products are said to be co-extruded.
 The layers may be made of the same or different
materials, colored or uncolored material, or recycled
and virgin materials.
 The main difference between multiple-layer and
single-material extrusion blow molding is in the
extrusion system. In co-extrusion, each material is
extruded from its own extruder.
 Examples of products made from this process are
ketchup bottles and automotive gas tanks.
Arrangement of Extruders for Co-extrusion

 An arrangement of extruders to produce co-extruded,

multilayer structures is illustrated in Figure 5.8.

 FIGURE 5.8-Page 316: Co-extrusion blow molding.

Multilayered Structures

 A co-extruded, multilayered structure (Figure 5.9a)

may be created to provide one or more characteristics
that cannot be provided by a single-layer product.

 for example, a better heat barrier or increased

resistance to permeation.
 or that a costly color be used in only one layer of the
structure instead of throughout the entire wall
thickness.
Co-extrusion Systems
 The extrusion system in co-extrusion blow molding
must supply several streams of melted material to the
die simultaneously.
 Some streams are smaller, by design, in volume than
others, in order to produce thinner layers. The
processing conditions may also differ from one
material to another.

 See Figure 5.9b which shows a typical co-extrusion die

head.
 See Figure 5.9c, which illustrates the multiple layers in
a packaging container.
 FIGURE 5.9 (a) Multilayer structures; (b) multilayer extrusion die and
manifold delivery system; (c) multiple layers used in packaging applications.
5.2.4.1 Three-Dimensional Extrusion Processes
 Three types of three-dimensional technology methods
are available: (1) the suction blow module, (2) vertical
clamp parison manipulation, and (3) horizontal
segmented mold parison manipulation.

(1) The suction blow molding

 Suction Blow Molding: FIGURE 5.11(Page 319) Suction

blow molding.
(2) Vertical clamp parison manipulation

 Parison Manipulation In the vertical clamp method

the mold opens vertically, the lower half slides out, the
parison is placed in the cavity, and the mold slides
back and blows (Figure 5.12). This method is ideal for
multilayer applications: for example, fuel filler pipes.
Conventual mold halves provide a lower mold cost.
The mold is also very accessible, and double-clamp
stations can be used for higher volumes (Figure 5.13-
Page 320).

 FIGURE 5.12(Page 319) Vertical clamp method.

 FIGURE 5.13 Integrated mounting. (Courtesy of SIG Kautex, Inc., North Branch, NJ.)
 (3) Horizontal segmented mold parison manipulation

 In the segmented mold/horizontal clamp process

(figure 5.14) the parison is extruded, and as the mold
begins to close, the parison is inflated. Then the
parison is manipulated to the cavity configuration and
the mold completes closure, cools, and opens with part
ejection. The parison manipulation is accomplished
with A sixaxis robot. Complex shapes can be produced
by using segmented mold technology, with the
incorporation of value-added design features through
the use of A clamp function and pinch-off for twin
tubes, brackets, and so on. The part quality is high due
to the minimum contact between parts and mold.
 FIGURE 5.14(Page 320) Horizontal clamp.
5.2.4.2 Double-Walled Parts and Containers
 A typical part is shown in Figure 5.15a.
 The parison is usually produced on a continuous
extrusion machine with a transfer parison into a mold
or a shuttle press (Figure 5.15b). In Figure 5.15c the
parison has been prepinched on the bottom. It has
been preblown with low pressure to form a pillow. As
the mold closes, the parison bulges and forms over the
male form. The side and top of the parison begin to be
trapped around the edges, essential for the successful
double-walled part (Figure 5.15d). The mold closes
further, with air preventing the walls from collapsing
(Figure 5.15e). Cooling and high-pressure air are used to
conform the mold core and cavity (Figure 5.15f ). The
high-pressure air is usually blown through a hollow
needle.(see page 321 for figures 5-15)
5.2.5 Injection Blow Molding
 Injection blow molding is used to produce a molded
parison called a preform.
 Injection blow molding is usually preferred over
extrusion blow molding for making small parts that
require high production volumes and closer control of
dimensions.
 The injection blow molding process occurs in two steps:
(1) injection molding a preform onto a support pin or
core, which provides neck threads that are already
formed to their required dimensions; and (2) blowing
the preform, still on the support(core) pin, to its final
shape in a separate mold(Figure 5.16-Page322).
5.2.5.1 Injection Blow Molding Machine
 In phase 1(injection station) of this process, the preforms are
molded by injecting the plastic material into a matched
metal mold, consisting of top and bottom split cavities, over
a core that forms the inside of the tubular preform. The
preforms are allowed to cool only long enough to hold their
shape.
 In phase 2(blow station) the mold opens and the hot,
semiviscous preforms are indexed to the next station (Figure
5.18), where split cavities in the shape of the part are closed
over the preforms. Here, the hot preforms are blown to the
shape of the cavities, then cooled.
 In phase 3(ejection station) the blow molds open and the
parts are indexed to the next station for ejection.
 In this three-phase process, all three phases take place at the
same time (Figure 5.19).
 FIGURE 5.18 Uniloy Milacron transfer turret, indexing
injection-molded performs on cores to blowing station.
 FIGURE 5.19 Three-station injection blow molding machine.
 The majority of machines are of the three-station type
described, with 120° indexing and matching injection
and blow molds.
 Special four-station machines are indexed on 90°
turns, with the fourth station being used for special
conditioning of the parison core rod after stripping
(pick-off) and before blowing (Figure 5.20-page 324).
 Four-station machines are often used for two-color or
multicolor bottles.
5.2.5.2 Stretch Blow Molding
 Stretch blow molding [referred to earlier as injection
stretch blow molding (ISBM)] involves: 1)conditioning
(heating) a molded and cooled preform to a specific
temperature, 2)closing it in the blowing mold, 3)then
very quickly stretching it in two directions, length and
diameter.
 Often, a rod is used to stretch the hot preform in the
axial direction, with air pressure then used to stretch it
in the radial direction.
 Apllication of this type of Molding:
improve impact strength, transparency, surface gloss,
gas barrier, and stiffness properties.
 FIGURE 5.21:
with the most
common application
for stretch blow
molding being the
soda bottles made of
clear or tinted
polyethylene
terephthalate (PET)
 FIGURE 5.22 Injection stretch blow molding machine manufactured by
Jomar Corporation,
5.2.6 Control System

 FIGURE 5.23
Uniloy Milacron
Carmac 486
process controller
for extrusion blow
molding machines.
 5.2.6.1 Reprogramming
 5.2.6.2 Universality
 5.2.6.3 Safety
 5.2.6.4 Troubleshooting
 5.2.6.5 Ancillary Control
 5.2.6.6 Open- and Closed-Loop Control
 5.2.6.7 Statistics
 5.2.6.8 Automatic Quality Control
5.2.7 Advantages of Extrusion and Injection
Blow Molding
5.2.7.1 Extrusion Blow Molding
 The blow molding process is a natural production
process for containers and hollow parts. It is the
preferred process for high-volume containers for
packaging applications such as food, personal care
items, and household products, as well as for industrial
high-strength applications such as automotive and
agricultural tanks, pressure vessels, and air ducts
Figures 5.24 to 5.27 show several examples of blow-
molded parts.
FIGURE 5.24 Cannondale bike bellows.
FIGURE 5.25 Panels.
FIGURE 5.26 Assorted bottles and containers.
FIGURE 5.27 Medical prescription containers.
5.2.7.2 Injection Blow Molding

The main advantages of injection blow molding are:

 There is no scrap or flash to trim and reclaim.

 The neck finish and details are very accurate and of
high quality.
 There is no process weight variation.
 Injection blow molding typically offers the lowest part
cost for high-volume bottles weighing 37 g or less.
5.2.8 Disadvantages of Extrusion and Injection
Blow Molding
5.2.8.1 Extrusion Blow Molding
 A disadvantage of blow molding is uneven wall thickness.
Although this may be minimized with programming, the wall
is usually thicker at pinch-off areas and thinner in corners.
The tendency of thicker walls to shrink more in the center of
the part has to be compensated for in the product design. For
example, rectangular containers usually have outwardlycurved
surfaces.
 Another disadvantage is that close dimensional tolerances
are difficult to achieve, the exception being bottle threads
produced by injection blow molding. The accuracy of surface
finishing details on extrusion blow molded products is also
relatively low.
5.2.8.2 Injection Blow Molding

The disadvantages of the injection molding process are:

 The cost of tooling is higher than for extrusion blow

molding.
 Bottle sizes and shapes are limited to an ovality ratio of
2 : 1 and a blow-up ratio no greater than 3 : 1.
 Slightly offset necks are possible with this process, but
handles are not.