DEPARTMENT OF MANUFACTURING ENGINEERING

FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING

UNIVERSITY TUN HUSSEIN ONN MALAYSIA
86400 PARIT RAJA, BATU PAHAT
JOHOR

BDX10902 MANUFACTURING TECHNOLOGY 1

INDIVIDUAL ASSIGNMENT 1
TOPIC: MANUFACTURING OF PLASTIC BOTTLES (PET)

NAME : MUHAMMAD AQIL BIN AHMAD BAIDZOWI

MATRIC NO :
SECTION :1
LECTURE’s NAME : SIR KAMARUDDIN BIN KAMDANI
SIR NOOR HAKIM BIN RAFAI
DUE DATE :
 TABLE OF CONTENT

TITLE PAGE
Introduction 3-4
Manufacturing Process 5 - 12
Quality Control and Quality Assurance 13 - 14
Detail Costing and Economics of Producing the Product 15
Reference 16

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 INTRODUCTION

The plastic bottle industry has been on boom since its advent, all thanks to the high
durability it offers. The wide range application of plastic bottles in almost every industry makes
them the most popular choice. Plastic bottles are highly versatile items with multiple uses.
Plastic bottle manufacturing takes place in stages. Typically, the plastic bottles used to hold
potable water and other drinks are made from polyethylene terephthalate (PET), because the
material is both strong and light. To understand the manufacturing process, it is helpful to first
examine the compositions of (PET).[1]

Figure 1: Plastic Bottle

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 Polyethylene Terephthalate is a thermoplastic polymer that can be either opaque or
transparent, depending on the exact material composition. As with most plastics, PET is
produced from petroleum hydrocarbons, through a reaction between ethylene glycol and
terephthalic acid. To produce plastic bottles, the PET is first polymerized to create long
molecular chains.[1]

Polymerization itself can be a complicated process and accounts for many of the
inconsistencies between one batch of manufactured PET and another. Typically, two kinds of
impurities are produced during polymerization, diethylene glycol and acetaldehyde. Although
diethylene glycol is generally not produced in high enough amounts to affect PET,
acetaldehyde can not only be produced during polymerization but also during the bottle
manufacturing process. A large amount of acetaldehyde in PET used for bottle manufacturing
can give the beverage inside an odd taste.[1]

Once the plastic itself has been manufactured, the bottle manufacturing process can
begin. To ensure that the PET is appropriate for use, numerous tests are done post-
manufacturing to check that the bottles are impermeable by carbon dioxide (which is important
for bottles that carry soda). Other factors, such as transparency, gloss, shatter resistance,
thickness, and pressure resistance, are also carefully monitored.[1]

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 THE PRODUCTION OF PET BOTTLES

Usually PET bottles are manufactured using 2 different methods.

These are:

I. One – step “Hot Perform” method.

II. Two – step “Cold Perform” method.

ONE – STEP “HOT PERFORM” METHOD

An efficient machine is put into use for producing bottles on a large scale in one single
step, from PET granule to finished bottles, all the processes are done in one integrated machine.
The process starts from the injection mold of the preform until the removal of the preform from
the injection cavity, to the stretch blow of the preform until it became a bottle all in one
machine, while the temperature remains constantly high during the whole process. 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.[2]

Figure 2: One – Step Method Machine

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 TWO – STEP “COLD PERFORM” METHOD

This method involves two individual machines for carrying out the injecting and
blowing procedure. The preform is injected into shape on the first machine, and then the
preform is reheated as 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 machine is 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.
Usually the Two – Step Method is used in production of PET bottles.[2]

Figure 3: Two – Step Method Machine

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 DRYING AND DEHUMIDIFYING OF PET

PET is hygroscopic, when exposed to the atmosphere it will readily absorb water vapor from
the surrounding air. The migration of water vapor into the PET granules occurs over time and
will eventually slow and stop when the moisture content reaches a state of equilibrium with
that of the surrounding air. At that equilibrium point, the water vapor within the PET granule
will be evenly distributed throughout the pellet’s interior. The water molecules are attracted to
the polymer chains, forming a strong intermolecular bond. That bond is what makes drying
PET difficult. Even a small amount of moisture in PET will cause a chemical reaction
(hydrolysis) when the polymer is heated above its melt temperature.[3]

➢ Oven Dry
o The drying is done at a temperature of 110°C 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 and the dried
PET is moved manually.
➢ Hopper Dryer
o The widely used method of drying PET as it very economical and works along
with an autoloader, therefore the process is continuous and automatic.

Figure 4: Hopper Dryer

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

Figure 5: Industrial Dehumidifier

The optimum drying temperature would be about 150~170°C. 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.

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 INJECTION MOLDING OF THE PET PREFORM

Figure 6: Injection Molding Machine with Essential Equipment Attached.

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

Figure 7: Schematic Illustration of the Injection Molding PET Bottle Process

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 The process is simple, the heated PET which is in the molten form is injected into the
injection chamber, by rotation of the screw barrel within the machine until the chamber is full.
Once the chamber is full, the screw pushed forward 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 275°C, at the
middle of the machine about 282°C, at the nozzle about 280°C. And at the runner the
temperature should be around 270°C for the bottle formed to have optimum specifications.
(Those temperature may vary a little depending on the design of the mold)

Figure 8: PET Preform Mold

Figure 9: Preform is Being Heated

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Subsequently the molten plastic within the mold, called the preform, should be cooled. The
cooling water is used to cool the preform and should be in the temperature range between
15~20°C, 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 from the mold. Now
the preform is reheated to the suitable temperature until it is suitable for the blowing process.

Figure 10: Water Chiller PET preform

Figure 11: PET Preform

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 EXTRUSION BLOW MOLDING OF THE PET PREFORM INTO A BOTTLE

Extrusion Blow Molding is one of several blow molding methods to produce plastic
bottles, jars and jugs. It is a common blow molding technology used to process many different
plastics, including HDPE, PVC, PC, PP, and PETG and also very common with bottles
requiring multi – layer technologis.[4]

A hot tube of plastic material, called a parison, is dropped from an extruder and captured
in a water cooled mold. Once the molds are closed, air is injected through the top or the neck
of the container, just as if one were blowing up a balloon. When the hot plastic material is
blown up an touches the wall of the mold, the material “freezes” and the container now
maintains its rigid shape.[4]

When a bottle is produced using blow molding method, excess is created when the mold
closes around the parison. This “flash” must be removed to complete a finished bottle or jar.
Flash at the bottom (called the tail), the top (the moil) and for handled ware – a “handled slug”
needs to be trimmed. Typically, the flash is removed upon mold release (trimmed in mold). For
bottle with handles (handleware), offset neck and special circumstances, the flash is extracted
via a secondary operation downstream.[4]

Figure 12: Extruded Blow Molding Processes

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 POSSIBLE DEFECTS WHILE PRODUCTION OF PET BOTTLES

PET bottles or container are made out of PET preforms. So, to make the best bottles, it
is very important that the preforms are defect free. And to make preforms defect free, it is
equally important to know the defect and it’s causes very well.[5]

1. Marble or Nacre Tint

PET preforms majorly get rejected due to Marble Tint. Due to the Marble or Nacre
defects, the bottle gives uneven appearance after some period of time. Causes of this defect
usually occurs due to cold stretching or maybe due to overstretching. Marble tint caused due
to overstretching concentrates on one are of the bottle. On the other hand, due to cold stretching,
the whole structure of the preform gets affected.[5]

This defect can be easily rectified by taking appropriate measures during preform
manufacturing. A stringent quality check is required to perform. The cooling temperature needs
to be controlled by adding some lamp lights. This increases the percentage of heating to a
certain level.[5]

2. Folds Around Stretching Rod on The Bottom of The PET Bottles.

PET bottles have defects in the form of folds at the bottom when un-stretched materials
get collected. This creates folds on the lower bulge which create cavity on the gate runner
where the thickness of the material is more. The defect is initiated in the form of the cavity
where the rod touches the bottom of the preform. The defects in the form of folds usually crack
the bottles from the folded area. There are numerous cases due to which the defect in the form
of folds occur at the lower part of the PET bottles, like:

i. Due to insufficient blowing pressure

ii. Delay in the process of pre-blowing
iii. Due to high amount of pressure
iv. At the time of stretch blown

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This defect can be rectified by assuring the quality of the preforms using various test methods
like:

i. Enhance the rate of flow

ii. Enhance the pressure of blow moulding
iii. Never forget to start the process of pre – blowing earlier
iv. Verify the heating temperature and ensure proper and equal material distribution

Figure 13: The PET Bottle Production Process

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 MANUFACTURING COST

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.[8]

Machinery Number Malaysia Ringgit (RM)

Injection Molding Machine 1 41391.00
Blow Molding Machine 2 44150.00
Compressor 1 8278.20
Cooling Tower 1 8278.20
Chiller Unit 1 4415.00
Lather 8ft, refurnished 1 6071.00
Lathe 5.5ft 1 3973.50
Pillar Drill 26 inches with pump 1 2759.40
Facer 1 8278.20
Shaper 1 6899.00

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.[8]

Others Growth Rate

Electricity 10%
Wages 10%
Office equipment 10%
Machine maintenance 5%

Raw Material Consumption per Bottle And the final costs.[8]

Cost (Malaysia Ringgit) per 100 Cost (Sterling Pounds) per 100
Size Weight
Bottles Botttles
0.5
15.5 8.00 1.45
Liter
1.5
33.3 17.30 3.15
Liter
5 Liter 74.7 38.70 7.00

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 REFERENCE

1. https://www.thomasnet.com/articles/materials-handling/plastic-bottle-manufacturing/

2. https://sommetpolymers.com/pet-preform/pet-
bottles/#:~:text=One%2D%20step%20'hot%20perform',into%20a%20crystal%20clea
r%20bottle.

3. https://www.ptonline.com/articles/how-to-dry-pet-for-container-applications

4. https://www.oberk.com/packaging-crash-course/what-is-extrusion-blow-
molding#:~:text=Extrusion%20Blow%20Molding%20is%20the,were%20blowing%2
0up%20a%20balloon.

5. https://www.prestogroup.com/articles/causes-solutions-of-defects-that-occur-in-
production-of-preforms-pet-bottles/

6. https://www.intouch-quality.com/blog/plastic-inspection-protocols

7. https://www.intouch-quality.com/blog/injection-molding-defects-and-how-to-prevent

8. http://newengineeringpractice.blogspot.com/2011/08/manufacturing-of-plastic-
bottles.html

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