Newly Developed Pneumatic Solution Ensures Model Bottles

Laatzen (Germany), 29.08.2017 | News

Controlled blow molding process reduces material and energy requirements while optimizing PET bottle formation

With Aventics’ latest pneumatic solution, a world first, users can now monitor the pre-blow molding process in the production of PET bottles online, in real time, and immediately make any necessary adjustments. This results in reduced material and energy consumption during high-throughput PET bottle production. For the first time, PET bottle formation can now be controlled and adjusted during the blow molding process. Aventics will present this solution at the drinktec 2017.

With this new solution based on proportional technology, Aventics is entering uncharted technological territory. In collaboration with a major filling company, the pneumatics specialists performed extensive research on the blow molding process. By combining a proportional valve, control electronics, and software, the solution records the actual values occurring during the process and compares them with the set points.

The new solution is intended for applications in the pre-blowing process. The set points for this step can either be stored in the electronics or transmitted via all common realtime Ethernet protocols and fieldbuses. During a blowing period of around 200 milliseconds, enough control cycles are available to precisely control bottle formation. This allows process technicians to intervene as needed, for example to reduce material consumption and fine-tune the formation of the bottle wall. Additional energy savings are possible by lowering the pressure level or reducing the furnace temperature.

Process data taken from the analysis can be used to derive continual improvements. At the same time, quality documentation is carried out in order to safeguard and track the process. In addition, trend analyses of the data enable the detection of wear before a failure can occur. Condition monitoring notifies maintenance early on to be able to carry out the necessary work in planned maintenance breaks.

The electropneumatic solution also meets new requirements in bottle production resulting from the trend towards more and more complex PET bottle shapes and smaller batches. As a software-based solution, the bottle formation process can be changed easily, without any mechanical alterations, and specific to each blowing station on the machine. The software can also automatically control process events, for example reaching the yield point and target bottle volume, according to specifications and keep them constant provided no wear limits have been reached. Once saved, parameters for a bottle type or specific material can be opened and activated at any time, significantly reducing waste during start of production. In close collaboration with product designers, the developers at Aventics validated numerous sample settings during the pilot production phase of new bottles.

At drinktec 2017, the world’s leading trade fair for drink and liquid food technology, Aventics will present this new solution to the professional public for the first time. The pneumatics specialists can be found in hall A3, stand 327, from September 11 to 15, 2017.