PRODUCTION TECHNOLOGY

Term paper/Assignment
GROUP 10
NAME REG NO
Samuel Omondi Ojunga E022-01-1402/2021
Simon Muiruri Ngugi E022-01-1353/2021
Marc Abel E022-01-1411/2021
Andrew Ongubo E022-01-2650/2021
Dennis Muthumbi E022-01-1351/2021
Blow Molding of Polymers
Blow molding is a type of plastic forming process for creating
hollow plastic products made from thermoplastic materials.
The process involves heating and inflating a plastic tube known
as a parison or preform. The parison is placed between two
dies that contain the desired shape of the product. Air is then
supplied to expand the tube causing the walls to become
thinner and conform to the shape of the mold. Once the
blowing process is complete, the product is then cooled,
ejected, trimmed, and prepared for the secondary processes
Blow molding is a significant manufacturing process in production technology because;
• Cost-effective: Blow molding is a low-cost manufacturing process compared to other methods, such as injection molding or
rotational molding. The process requires less material and energy, making it an economical choice for mass production of
hollow objects.
• Versatile: Blow molding can be used to create a wide range of products, from small custom plastic bottles to large storage tanks
or big plastic drums. The process can also be used with different types of thermoplastic materials, such as polyethylene,
polypropylene, PET, PVC, and co-polyester.
• Simple process: Blow molding is a simple process that involves inflating or blowing a thermoplastic molten tube (parison) in the
shape of a mold cavity. The process involves fewer steps and requires less equipment than other manufacturing processes.
• Sustainable: Blow molding is a sustainable manufacturing process that produces less waste and uses fewer resources than
other methods. The process can also be used with recycled materials, making it an eco-friendly choice for production.
• There are three main types of blow
molding techniques: extrusion blow
molding, injection blow molding, and
injection stretch blow molding
1. Extrusion blow molding: This is the
most common type of blow molding
process. With extrusion blow molding,
plastic is heated until it turns from a solid
state to a liquid state. The liquefied plastic Extrusion blow molding:
is then forced into an extrusion machine.
The extrusion machine also forces air into (1) and (2) parison pinches at the top and sealed at the bottom
around a metal blow pin as the two halves of the mold come
the melted plastic, essentially inflating it together
to create a hollow interior. Once finished, (3) the tube is inflated so that it takes the shape of the mold cavity
(4) mold is opened to remove the solidified part.
the plastic is cooled, typically at room
temperature, and the newly created
hollow object is ejected and removed
from the mold. Extrusion blow molding
allows the molder to make the most
2. Injection blow molding: Injection blow
molding involves the "injection" of
material, including heated glass and
plastic, into a mold. The heated material
is typically forced into a core pin, after
which the pin rotates around a molding
station where the heated material is
blown into the finished shape of the
bottle. The largest market currently uses
the material polyethylene terephthalate Injection blow molding:
(PET). This method has both advantages 1. Parison injection molded around a blowing rod
and drawbacks. On the plus side, it's 2. Injection mold is opened and parison is transferred
ideal for making very precise bottlenecks, to a blow mold
thanks to the core rod used in the 3.
4.
Soft polymer is inflated to conform to a blow mold
Blow mold is opened and blown product is
injection portion of the process removed.
 Extrusion vs. Injection Blow Molding
Extrusion
• Bottles over ½ pound
• Tooling costs are 50% to 75 % less
• Generates 20 to 30% scrap
• Additional machinery needed to grind
scrap
• Total cycle time is shorter
• Wider choice of resins
• Greater flexibility in part design
Injection
• Long runs and smaller bottles
• No trim scrap
• Higher accuracy in the final part
• Uniform wall thickness
• No seam lines or pinch marks
• Better transparencies
• Improved mechanical properties
3. Injection stretch blow molding: Injection
stretch blow molding combines the injection
molding and blow molding processes. The
plastic is first molded into a solid preform, to
create a threaded bottle neck. Once the
preform cools, it is fed into a stretch blow
mold machine. The preform is then reheated
using an infrared heater and blown into a A: Stretch-Blown Pin; B: Air Entrance; C: Mold Vents; D: Preform;
E: Stretch Rod Extended; F: Cooling Channels
plastic bottle with forced compressed air
• produces a part with biaxial molecular alignment. In the process a preform,
or parison, elongated mechanically in the mold and than expanded radially
in a blowing process. A desirable resulting molecular orientation yields a
material with increased strength. This means that products that are
strength-based designs can be produced using less material than if they
were to be produced using simpler blow molding techniques.
• Materials used in blow molding: Blow molding can be used with a wide range of
thermoplastic materials, such as polyethylene,PET, PVC, and co-
polyester,Polyolefins;HDPE,LDPE,Polypropylene (PP)
• . The choice of material depends on the application and the desired properties of
the final product.
One critical requirement is that the polymer must have good melt strength.

PET bottles are excellent barrier materials and

are widely used for soft drinks
 Polyolefins
ADVANTAGES
The polyolefins are easy to process and have the
advantage of good electrical properties, moisture
resistance, and low cost.

DISADVANTAGES
Sensitive to oils and can have stress crack
problems

PROCESSING PARAMETERS
These resins are usually blow
o
molded in the range of 320 –
o
410 F. Mold temperatures should
o o
range from 50 – 100 F.

MARCH 2017 NEERAJ KUMAR

 Polyvinyl Chloride (PVC)
ADVANTAGES
Very desirable properties of clarity, smooth
surface low glass and aroma permeation,
high stiffness with low wall thickness, high
chemical resistance, and easy labeling
and printing

DISADVANTAGES
Very temperature sensitive, therefore not
normally injection blown because the
process requires two heat cycles

PROCESSING PARAMETERS
Typical melt temperature range for PVC is
o o
375 – 420 F.

MARCH 2017 NEERAJ KUMAR

 Polyethylene terephthalate (PET)
ADVANTAGES
Easily recycled, very lightweight, it makes
a good gas and fair moisture barrier. It is
strong and impact-resistant. It is naturally
colorless and transparent.

DISADVANTAGES
Have to be careful to avoid a temperature
that is two high or acetaldehyde forms.

PROCESSING PARAMETERS
Temperature range for PET to blow mold
o o
is 200 – 212 F. Mold temperatures should
o o
be in the range of 35 – 40 F

MARCH 2017 NEERAJ KUMAR

• Blow molding is a manufacturing process used to create
hollow objects made of plastic. The process involves
several steps, including parison extrusion, mold clamping,
inflation, cooling, and ejection.
• Plastic feeding: The first step in the blow molding process
is plastic feeding. Plastic pellets are fed into the machine
and conveyed into the extruder. The extruder melts the
plastic and forms it into a parison or preform.
• Mold clamping: The mold is clamped shut and the parison
is held in place.
• Inflation: Compressed air is blown into the parison, inflating it to the shape of the
mold cavity. The air pressure then pushes the plastic out to match the mold. The
amount of plastic used and the air pressure determines how thick the final
product is.
• Cooling: Once the plastic has taken the shape of the mold, it is cooled to solidify
the final product.
• Ejection: The mold is opened, and the newly created hollow object is ejected and
removed from the mold.
• The key concepts, principles, and relevant theories of blow molding include:
• The process of blow molding: The process of blow molding involves several steps, including
parison extrusion, mold clamping, inflation, cooling, and ejection. The process begins with
softening plastic by heating a preform or parison. The parison is a tube-like piece of plastic
with a hole in one end through which compressed air can enter. The plastic is then inflated
to the shape of the mold cavity and cooled to solidify the final product.
• The role of temperature, pressure, and cooling in blow molding: Temperature, pressure,
and cooling are critical factors in the blow molding process. The plastic must be heated to a
specific temperature to soften it enough to be inflated. The air pressure must be carefully
controlled to ensure that the plastic takes the shape of the mold without thinning or
warping. Cooling is necessary to solidify the final product and prevent deformation.
• The physics of polymer deformation during blow molding: The physics of polymer
deformation during blow molding is complex and involves several factors, such as the
viscosity of the plastic, the rate of deformation, and the elasticity of the material. The
plastic must be heated to a specific temperature to soften it enough to be inflated. The air
pressure must be carefully controlled to ensure that the plastic takes the shape of the mold
without thinning or warping. Cooling is necessary to solidify the final product and prevent
deformation.
• Advantages of blow molding:
• Blow molding is a cost-effective and versatile
manufacturing process that can be used to create a
wide range of products.
• The process requires less material and energy than
other methods, making it an economical choice for
mass production of hollow objects.
• Blow molding is also a sustainable manufacturing
process that produces less waste and uses fewer
resources than other methods.
• Wide range of materials: Blow molding supports
various materials, including high-density polyethylene
(HDPE), polypropylene (PP), and polyethylene
terephthalate (PET). This versatility allows
manufacturers to select the most suitable material for
their specific application requirements.
• Fast production rates: Blow molding allows
manufacturers to create high quantities of hollow
plastic products in a short period of time. The process
is automated, which helps to speed up the production
process and reduce labor costs.
• Disadvantages of blow molding:
• Blow molding has some limitations, such as the
difficulty of creating complex shapes
• the potential for defects, such as flash, thinning,
and warping
• Plastic waste: Blow molding contributes to plastic
waste, which can have adverse effects on the
environment. Plastic is not biodegradable and
typically makes its way into landfills.
• Design limitations: Blow molding has limitations in
the design of products. Hollowed-out custom
plastic bottles, rectangular plastic cases, and other
similarly shaped objects are usually the best fit for
this process.
• Less design flexibility: Blow molding has less
design flexibility compared to other manufacturing
processes, such as rotational molding. The tooling
cost is also high compared to rotomolding.
• Surface finishes: The surface finishes produced by
blow molding are not always aesthetically
pleasing.
• Blow molding has a wide range of applications across various
industries. Some of the applications of blow molding include:
• Packaging industry: Blow molding is widely used in the packaging
industry to produce bottles, containers, and jars for various
products such as water, juice, carbonated beverages, shampoo,
and detergent. The process is cost-effective and allows for the
production of large quantities of products in a short period of
time.
• Automotive industry: Blow molding is used to produce various
automotive parts such as fuel tanks, air ducts, and cooling system
overflow containers. The process allows for the production of
lightweight and durable parts that meet the industry's stringent
safety standards.
• Medical industry: Blow molding is used to produce medical
devices such as inhalers, nebulizers, and other respiratory
products. The process allows for the production of sterile and
disposable products that meet the industry's strict quality
standards.
• Consumer goods industry: Blow molding is used to produce a
wide range of consumer goods such as toys, lawn and garden
items, and household items. The process allows for the
production of lightweight and durable products that are cost-
effective.
• Petrochemical industry: Blow molding is used to produce
containers for storing lubricants and petrochemicals. The process
allows for the production of multilayered containers that can
store contaminated lubricants and petrochemicals.
• Blow molding has seen several breakthroughs in recent years,
including the following:
• Automation: Automation has become increasingly prevalent in
blow molding, allowing for faster and more efficient production.
• Infrared heating: Infrared heating is a more efficient and precise
way of heating PET preforms before they are stretched and
blown into a mold. This technology uses infrared radiation to
heat the preforms evenly, reducing the risk of overheating and
ensuring consistent results.
• 3D printing: Injection blow molding machine manufacturers use
3D printing to create prototypes and test designs before
committing to full-scale production. CAD/CAM software allows
injection blow molding machine manufacturers to create custom
molds for specific products, improving the efficiency and quality
of the manufacturing process.
• MuCell® foaming solution: Trexel has extended its license and
royalty-free Trexel MuCell® foaming solution to blow molded
components across other industries. This solution offers up to
20% weight reductions without compromising impact strength
and product performance.
• Sustainability: Blow molding companies are increasingly focused
on sustainability, with trends toward reducing the use of virgin
plastics, increasing the use of PCR, and reducing energy
consumption. There is also a focus on recycling and the circular
economy, with companies producing child-sized watering cans
from recycled PE fishnets and bottles made from 100% rPET.
• Blow molding is expected to continue to grow in popularity due to its cost-effectiveness, versatility, and
sustainability. Advancements in materials and equipment for blow molding are expected to improve the
quality and efficiency of the process.
• Some of the emerging trends and future prospects in blow molding include:
• Automation: Automation has become increasingly prevalent in blow molding, allowing for faster and more
efficient production. This trend is expected to continue in the future, with more advanced automation
technologies being developed.
• Infrared heating: Infrared heating is a more efficient and precise way of heating PET preforms before they
are stretched and blown into a mold. This technology uses infrared radiation to heat the preforms evenly,
reducing the risk of overheating and ensuring consistent results.
• Sustainability: Blow molding companies are increasingly focused on sustainability, with trends toward
reducing the use of virgin plastics, increasing the use of PCR, and reducing energy consumption. There is
also a focus on recycling and the circular economy, with companies producing child-sized watering cans
from recycled PE fishnets and bottles made from 100% rPET.
• Increased process simulation: Currently, there is little computer simulation available to aid the blow molding
process. However, industry experts expect to see better simulation options in the future. Ultimately, they’ll
enhance performance, decrease cycle time, and reduce the weight of finished products.
• Machine upgrades: There’s an excellent chance that more blow molding manufacturers will have the ability
to upgrade or retrofit existing machinery. Through the use of mechanical and hydraulic components, blow
molding machines will become more reliable and competitive.
• Emerging markets: The Asia-Pacific region is expected to be a significant market for blow molding in the
 CONCLUSION
• In conclusion, blow molding is a manufacturing process used to create hollow
objects made of plastic. The process involves several steps, including parison
extrusion, mold clamping, inflation, cooling, and ejection. Blow molding has
several advantages, including cost-effectiveness, design flexibility, and a wide
range of materials. However, it also has some disadvantages, such as plastic waste
and design limitations. The future of blow molding looks promising, with
emerging trends such as automation, infrared heating, sustainability, increased
process simulation, machine upgrades, and emerging markets. These
advancements are expected to improve the efficiency, quality, and sustainability
of the blow molding process, making it a more attractive option for
manufacturers across various industries.
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