POLYSURE/ TECHNICAL GUIDE TO Blow Molding Process HPCL-Mittal Energy Limited Customer Services & Development Center ‘4.27, Sector 65, Noida ~ 201301 U.P. INDIA Phone: 0120-4634972Contents Introduction 3 Blow Molding Process Deere ah cat Era hae eco Neer ers a LETC el Colter acta tendo i aioe Ce Clan) tte Col ele elt) 7 eg eee cre CMO a fora C aCe isciacls ron Neer Molded Products rv) Troubleshooting Guide Sta Ca ACI Raed ae)\ INTRODUCTION used to manufacture hollow plastic parts by inflating a heated plastic tube until it fills a mold and forms the desired shape. The raw material in this process is a thermoplastic resin in the form of small pellets or granules, which is first melted and formed into a hollow tube, called a parison or a preform based upon the process of its formation. The parison or preform is then clamped between two mold halves and inflated by pressurized air until it conforms to the inner shape of ‘the mold cavity. Typical pressures are 25 to 150 psi, far less than for injection molding. Finally, after the part has cooled, the mold halves are separated and the part is ejected, B low molding is a manufacturing process that is, ‘The global blow molded plastics market size was valued at USD 75.7 billion in 2020 and is expected to grow at a compound annual growth rate (CAGR) of 3.3% in coming years, owing to the growing adoption of molded processes, that are prevalent for commercial | n general, there are three types of blow molding production of various types of articles. 1. Extrusion Blow Molding (EBM) 3. ContinuousExtrusion BM b. Intermittent type extrusion BM. Fig: Berusion Blow Mong Machine Wi Blow Molding Process Description plastics in the automotive industry for making lightweight automotive parts. Blow molded plastic parts are lighter in comparison to metal and provide excellent stiffness. Additionally, the innovations in molding technologies is expected to have a positive impact on the growth of the market in india in the next five years as the newer production processes are more energy efficient, time-saving and environment friendly. Plastic parts made from blow molding process are hollow, and thin-walled such as bottles and containers that are available in a variety of shapes and sizes. Small products may include bottles for water, liquid soap, shampoo, motor oll, and milk, while larger containers include plastic drums, tubs, and storage tanks. This technical article is @ brief overview of blow molding process, its benefits, applications, attributes of Polysure polyethylene grades and troubleshooting guide. 2. Injection Blow Molding (IBM) 3. Injection Stretch Blow Molding (IsBM) The blow molding process is meant for the manufacture of all types of hollow polymer products. But the way parison is produced, makes all the differences between the several methods of blow molding that have subsequently emerged. Whatever be the method, the basic process constitutes the following essential steps. = Melting of Polymer ~ Polymer pellet is heated inside the extruder for melting & homogenisation = Parison/Preform Formation — Molten polymerisextruded or injected through a nozzle- mandrel combination, so as to produce a tubular form or a parison Technical Guide to Blow Molding Process= Parison Sealing ~ One end of emerging parison is sealed by pinching & cutting the tubular form = Parison Positioning ~ Parison is lowered into the cavity of an open mold = Mold Closing ~Mold is closed and parison isinflated by blowing air through the open end. = Shaping ~ The inflated parison takes the shape of themoldcavity = Product Cooling ~ Polymer melt is allowed to cool for solidification = Mold Opening ~ Mold is opened and the part is ejected = Finishing-The lash, ifany, is trimmed 1. Extrusion Blow Molding (EBM) 1 Extrusion Blow Molding (EBM), plastic granules are fed into heated barrel, which convert granules into molten mass. Molten polymer is then passed through die head which contain die-mandrel combination to give shape of hollow tube known as parison. This parison isthen captured by closingit intoa Heated plastics Mould closes Compressed air extruded into hollow parisons gripped blown into parison tube (parison) inplace hich inflates 1 2 3 Continuous and Intermittent are two variety of Extrusion Blow Molding. In Continuous Extrusion Blow Molding the parison is extruded continuously and the individual parts are cut off by a suitable knife. In Intermittent blow molding there are two processes: straight intermittent is similar to injection molding whereby the screw turns, then stops and pushes the melt out. With the accumulator method, an accumulator gathers melted plastic and when the previous mold has cooled and enough plastic has accumulated, a rod pushes the melted plastic and forms the parison. In this case the screw may turn continuously or intermittently, with continuous extrusion the weight of the parison drags the parison and makes calibrating the wall thickness difficult. The accumulator head or reciprocating screw methods use cooled metal mold, Air is then blown into the parison from open end, inflating it into the shape of the hollow bottle, container, or part as per the shape of the mold. After the plastic has cooled sufficiently, the mold is ‘opened and the partis ejected. Parison Product is trimmed Finished product fils mouls and removed ready for next from mould production stage 4 5 6 Fig, 2: Extrusion Blow Molding Process hydraulic systems to push the parison out quickly reducing the effect of the weight and allowing precise control over the wall thickness by adjusting the die gap witha parison programming device. Process Advantage: = Low molding cost resulting from lower pressure used Low tool cost due to simple structure = Fast production due to small processing cycle = Abilityto mold complex part Process Limit = Lowstrength of the product tion: = Higher scrap generation through secondary operation (pinch-off trimming) ical Guide to Blow Molcing Process2. Injection Blow Molding (IBM) his is a very unique process. In this process, the starting product, which is called preform, is Injection molded rather than extruded from the polymer pellets. The preform consists of a fully formed bottle/jar neck with a thick tube of polymer attached, which will form the body, similarin appearance to atest tube witha threaded neck. Injection blow moldings the process whereby the plastic preformis injection molded and the preform travels on the core rod to the blow Injection molding prior to blowing molding station, where blow air enters through the core. rod and lifts the hot preform material off the core rod and forms it by air pressure to the design of the female blow mold. Often the preforms are preheated before being placed into the blow mold. A simplified sequence is outlined in below. Compared to its extrusion-based competitor, the injection blow- molding process has a lower production rate, which explains why itis less widely used Ain | v (ay Blow-molded part Blowing rod Icon unit Ss Ss ria One-way, air valve Injection mold + Blow mole’ a @ @) Injection blow molding: (1) preformis injection molded around a blowing rod; (2) injection mold is opened and preform is transferred to a blow mold; (3) soft polymer isinflated to conform to a blow mold; and (4) blow mold is opened and blown productis removed Process Advantages: Ability to produce threaded mold neck = Finished bottle without weld ine “ Fig. 3: Injection Bow Molding Process = Noscrapgeneration = High evel of dimensional accuracy Process Limitation: = Small capacity of the product = High machine & tooling costs * Compromise between preform wall thickness and blow up ratio 3. Injection Stretch Blow Molding (ISBM) njection Stretch Blow Molding (ISBM) involves. molding the plastic into a ‘preform’ using the Injection Molding procedure. When these preforms are produced, they include the necks of the bottles as well as threads, known as the finish. These preforms are then cooled and put through the Blow Molding process. In the IS8M process, the preforms are heated above theirsoftening temperature and then using blow molds, they are subjected to high-pressure air and blown into bottles. Typically, the preform is stretched with a core rod during the process. Process Advantages: = Fast production, high productivity = Less pressure (as core pin is used to stretch the heated preform), hencestress free products = Excellent visual and dimensional quality of the Products with high barrier, optical & mechanical properties. Process Limitations: = Costly machine = Limited product portfolio. Technical Gude to Blow Molding ProcessIC Injection moulded Proform secured Preform reform heated intoblow mould _ stretched with core rod mic Compressed air Product is Finished product simultaneously Femoved from ready for next blown in- preform mould production stage infiates to mould Fig 4: Injection setch Blow Molding Process Blow Molding Process Advantages it a favourable process over other types of B low molding holds many advantages that make molding. Some of these advantages includes: = Well suited to low and high production rates with versatile types of materials = Very fast production rate - Quick product revisions forincreased flexibility = Each part price is less than Rotational Molding (faster cycle) = One piece construction (no need to connect part halves) = Excellent ESCR (environmental stress crack resistance) = Choice between single and double or multi walled construction (Multilayer Blow Molding) = Easily replaceable parts & hence low maintenance cost = Processtomake hollow parts = Toolingisless expensive than Injection Molding = Excellent part performance under pressure = Trimand flash reusable into finished parts mw Blow Molding Resin Selecti — arts made from blow molding are hollow and thin-walled, such as bottles and containers that are available in a variety of shapes and sizes, Small products may include bottles for water, liquid soap, shampoo, motor (lubricant) oil, and milk, while larger containers include plastic drums, tubs, and storage tanks. Blow molded parts can be formed from 2 variety of thermoplastic materials, including the following. = High Density Polyethylene (HDPE) = LowDensity Polyethylene (LDPE) = Linear Low Density Polyethylene (LLDPE) = Polyethylene Terephthalate (PET) = Polyvinyl Chloride (PVC) = Polypropylene (PP) Polyethylene (HDPE) is most widely used rigid polymer for blow molding applications and it has good mechanical properties. Mechanical properties are strongly dependent on the crystallinity and density of the product. HDPE and LLDPE are more considered to be used in making bottles because they have higher crystallinity and density than PP, PP is not usually used to produce large & medium size bottles by extrusion blow moulding because its melt “Technica Gude to Blow Molding Processstrength at the molten state is lower than that of LLDPE and HDPE melts. Therefore, itis usually required to be injection blow molded, in which the cooling process of the preform is employed before inflation. PP is mostly used for special barrier, hot fill/ heat sterilisation, high stiffness & high ESCR applications. However, in case of low capacity bottles for IV fluid application, the products are manufactured from PP random copolymer by extrusion blow molding process, primarily due to their properties of contact clarity and stiffness. SBM process is used to manufacture Bottles/lars for the cosmetic, medical and food industry. Wi Effect of Resin Variables on Blow Molding Process Molecular Weight directly responsible for strength of polymer. a Molecular Weight MFI Stiffness 7 Die Swell 4 Melt Strength 12 Molecular Weight Mri Stiffness J Die Swell J Melt Strength | Molecular weight distribution is a function of catalyst system and polymerisation process. 2 Polyolefins with broad MWD are easier to process due to more shear sensitivity than the one with narrow MWD. 24 MWD (Broad) FRR Processability 22 MWD (Narrow) FRR Processability W 3 Stereo regularity measured by Isotacticity BA Isotacticity Xylene solubility | Stiffness Clarity J 32 Isotacticity J Xylene solubility? stiffness J Clarity 4 crystallinity of polymer impacts the density, stifess and ESCR of polymer 4a Crystallinity Density Stiffness 4 ESCR Stackability 42 Crystallinity Density J Stiffness W ESCR 7 Stackability 1 ‘Table 1 ~ Correlation between Resin & Product Property Polysure HDPE MEL Polysure HOPE grades serve the entire blow molding application range with 80155D, B0148D, BO0S3D and B0158S, which are produced by Chevron Phillips Advanced Dual Loop Slurry MarTECH™ technology and by Gas Phase Unipol PE Technology from Univation Technologies Wi Jo) eg Pd oe Lele Mle lm lem VCore cele respectively. These grades are primarily suitable for GPBM - Containers up to 20 L, MBM Containers up to 120 L and LBM up to 240 L applications. B0155D, B0148D, B0053D and BO1S8S combine exceptional processability with good melt strength and die swell, excellent ESCR, stack-ability and low parison sagging. Technical Gude to Blow Molding Process [idGPBM - Containers for Lube oils, Edible oils (upto 20 L) BO1S5D 0.35(I2) 0.955 Bo148D 10(I21) 0.948 Polysure HDPE B0053D 2.5(I21) 0.953 0158s 0.15(I2) 0.958 MBM - Shipping Containers, Jerry cans, Fuel Tank (upto 120 L) LBM - L Ring Drums, Lube oil Drums, Industrial Tanks (upto 240 L) GPBM - Containers for Lube oils, Edible oils (upto 20 L) ‘IMF in 9/1005 per ASTM 01238 **Density in gfe as per ASTM DISOS at 23°C Table 2~ Characters of Poysure HOPE Grades fr Blow Molding Appicaions Typical Properties of Polysure HDPE Good Melt Strength & Die Swell Excellent ESCR & Stackabilty Low Parison Sagging & Superior Stackability Good Melt Strength & Die Swell 10 a 2 “All the mechanical properties are determined on Compression Molded Test Specimen, prepared accordonce with ASTM D4703, Melt Flow Index (190°C & 2.16 kg) Melt Flow Index (190°C & 5 kg) Melt Flow Index (190°C & 21.6 kg) Density (23°C) Tensile Strength at Yield, Type IV Specimen. ‘Tensile Elongation at Break, Type IV Specimen, Flexural Modulus (196 Secant) Notched Izod impact Strength (23°C) Vicat Softening Point (10N) Heat Deflection Temperature (0.455 Mpa) Hardness ESCR (F50), 100% Igepal ASTM 1238 ASTM. 01238 ASTM. 01238 ASTM. 1505 ASTM, D638 (50 mm min) ASTM. 730A ASTM. 256A ASTM, 1525 ASTM 648 ASTM. 02240 ASTM. 016938, Table 3— Properties of Polysure HOPE Grades for Blow Molding Applications £/10 min /10 min 8/10 min siec MPa % MPa sien *c °c Shore D Hour 0.955 27 1000 150 125 75 63 35, 0.36 10 0.948 25 No Break 126 78 68 > 600 0.08 25 0.953 27 > 600 1000 No Break 127 80 68. 300 0.958 27 1050 150 125 75 63 140 “Technica Gude to Blow Molding ProcessPda eu aceon keer © Excellent Processability @ Good Melt Strength with Superior Die ‘Swell properties Polysure PP MEL Polysure PP grades serve the blow molding sector with RBO2RR & RBOZCR. These grades are Polypropylene Random Copolymer, produced by latest Lyondell8asell Spheripol I! Technology & primarily suitable for blow molding applications like IV Fluid Bottles, Small Blow Molded @ Low Parison Sagging 10, 18°, 000, Finished products offer Excellent ESCR & Superior Stackability Containers, and high Clarity Container applications. RBOZRR is specially additivated for medical applications. RBO2CR combine exceptional processability with superior melt strength and clarity due to the presence of clarifying agent. gtk. eee RBORR 2. Polysure PP RBO2CR 2 “Min g/10.05 per ASTI 01238 ‘Table 4~ characterises of Polsure PP Grades fr Blow Molding Applications IV Fluid Bottles, Small Blow Molded Containers High Clarity Containers, Bottles, Sheet, Ball Pen Refills Superior Melt Strength & Clarity Superior Clarity & Processability Technical Guide to Blow Molding ProcessTypical Properties of Polysure PP a Tensile Strength at Yield, Type | Specimen MPa ASTM D638 EEE Soe a Flexural Modulus (1% Secant) ASTMD790A MPa i Vicat Softening Point (10N) ASTM 1525 -°C “Al the mechanical properties are tested on Injection molded Test Specimen, prepared in accordance with ASTM D402 ‘able 5 ~ Properties of Polysure PP Grades for Blow Molding Applications BTA] Technicat Guide to Blow Molcing Processmaken ele Koen Excellent clarity Superior melt strength © Special additive suitable for medical applications Brn kee Recommendation for HDPE "= Barrel Temperature: 170- 210°C ® Die Head Temperature: 150 ~ 190°C ® Recommendation for PP "= Barrel Temperature: 190 ~ 230°C = Die Head Temperature: 190~ 210°C & Boel Bags should be stored in dry & dust free environment at temperature below 50°C and prevent from direct exposure to sunlight & heat to avoid quality deterioration. Rte cua Polysure Polyethylene grades are manufactured complying the requirements specified in 1S 10146 on “Specification for Polyethylene for its safe in contact with Foodstuff, Pharmaceutical & Drinking water”. Furthermore, the Additives added in this grade formulation compiles to the “Positive list of constituents for Polypropylene, Polyethylene and their Copolymers for its safe use in contact with Foodstuffs & Pharmaceuticals’ as lald down under IS 16738:2018. In ‘general, the additives & constituents used in the grade are in line with requirement laid down under FDA: CFR Title 21,177.1520, Olefin Polymers. Polysure Polypropylene grades are manufactured complying the requirements specified in IS 10910 on “Specification for Polypropylene & its Copolymers for safe use in contact with Foodstuff, Pharmaceutical & Drinking water”. Furthermore, the Additives added in this grade formulation compiles to the “Positive list of constituents for Polypropylene, Polyethylene and their Copolymers for its safe use in contact with Foodstuffs & Pharmaceuticals’ as laid down under IS 16738:2018. In general, the additives & constituents used in the grade are in line with requirement laid down under FDA: CFR Title 21,177.1520, Olefin Polymers. Technical Gude to Blow Molding Process ETmw Applications of Blow Molding Pro DPE resins are the choice for many applications due to resistance to cracking, stiffness and chemical resistance whereas PP random Consumer Products = Edible oll & House ware containers = Toys, Sporting Goods, Furniture "Cosmetic, Shampoo bottles Automotive = Car AC ducts, = Vehicle Fuel Tanks = Panels, Boots and cover Medical & Pharmaceutical = IVfluid bottles = Pouches for medicine = Medicine bottles = Health care equipment = Protective device Chemical Industries "Small and large ™ Engine oil containers containers for eens = Catalyst drums packaging Cosmetics Packaging ® Body Lotions Container = Shampoo Bottles = Moisturiser Container Other Applications = Pesticides bottles = Toilet cleaner bottles = Food Supplement Bottle Fig. 5~ Blow Molded Products fac) copolymers are mainly used for medical application. Various blow molding application are mentioned below- r Chevron Phillips MarTECH Advanced Dual Loop Technology has capabilities to produce broad and bimodal blow ‘molding grades with excellent resistance to crack growth, that serves niche MBM and LBM applications BP Technicat Guide to Blow Molcing ProcessWi Troubleshooting Guide For Blow Molding Process any a times, we face processing & performance related difficulties during manufacturing of blow molded articles. Although these issues may vary from machine to machine, but most of them can be addressed easily with Prat erates} Deets ROUGH SURFACE VARIABLE PARISON LENGTHS DIE LINES DRAWDOWN, PARISON SAG / STRETCH BLACK SPECKS IN CONTAINERS BUBBLES / FISH EYES PARISON NOT BEING BLOWN EXCESSIVE SHRINKAGE Presences of moisture Low blow air pressure Inadequate mould venting Low melt temperature Extruder screw rpm Surging of Polymer Uneven head temp = Contamination = Degraded resin Low melt temperature Damaged die or mandrel High parison temperature High melt index of resin High mold opening time Resin hang-up in die Material contamination Restricted blow air orifice Low mold temperature Tooling damage Wet / contaminated resin Defective blow timer Clogged blow lines Sharp pinch-off High mold temperature Low cooling cycle Low blowing air pressure Uneven parison thickness ‘Table Siow Molding Process Troubleshooting solutions Disclaimer: The information & data presented herein are typical values & should not be considered as specification and may be used as guideline only. HMEL does not undertake any responsibilty fr any outcome or results fram the adoption or replication of the above mentioned data & information there on for possible use for various applications. HMEL reserves the right to change the Information & data without any prior notice or information. The user wil solely be responsible for any process/product usage. proper selection of resin or little adjustment in ‘operating parameters, The probable cause and remedy for few generic issues arising during blow molding process are recommended here. Dry the mould cavities Increase blow air pressure Inspect and clean or repair mould vents Increase melt temperature Optimise the screw rpm Check swell ratio of polymer Check proper temperatures = Lower mandrel and purge = Check for foreign matter ‘Adjust temp in recommended zone Replace tooling / die Decrease stock temperature Decrease extrusion back pressure Use lower melt index resin Reduce mold open time Clean die surface Clean tooling Use clean resin Check the orifice for restrictions Increase air pressure & melt temp. Check too! Use dry resin & dust free resin Replace blow timer Clean blow lines Create more pinch area Reset cushion Decrease stock & Mold temperature Check mold cooling Increase blowing pressure mandrel and die Technical Gude to Blow Molding Process BE}Blow Molding Process Virgin resin aesthetically enhanced by colorants Polymer melted to obtain desired shape Technical Gude to Blow Molding ProcessParison formation before blowing End use of Blow Molded product Final product shaped Technical Gude to Blow Molding ProcessCustomer Services & Development Center MEL has chartered on a goal to emerge as a responsible player in the Petrochemical Industry. HMEL has set upa state-of the-art Customer Services & Development Center (CSDC) at Noida to strengthen its customer vvalue proposition through Research & Development. HMEU's CSDCis equipped with sophisticated and advanced testing equipment andis aptly designed to have flexibility which allows diverse modes of testing. We are committed to produce consistent quality products in line with industry needs & always stand by our customers for all-round support for product, application and market development initiatives. Accreditation of CSDC = This center is accredited to ISO/IEC 17025:2017 by National Accreditation Board for Testing and Calibration Laboratories (NABL}, Govt. of India. = Further, Customer Services & Development Center (CSDC), Noida has been recognized and registered as one of the key scientific and industrial R&D facility by Department of Scientific & Industrial Research (DSIR), Ministry of Science and Technology, Govt. of India. ee HMEL HPCL-Mittal Energy Limited INOX Tower, Plot No. 17, Sector-16A, Noida ~ 201301 (U.P), India. Tel: 0120-4634500 @wwwhmel.in