3-in-1 combiblock, combined with blowing, filling and capping. It is innovated and designed in the requirement of still pure water
and mineral water, which avoids friction of bottles during air conveying and helps reducing bottle weight to reduce cost.
1. Rotary Blow Molding Machine
1. Preform enters the heating machine from the preform unscrambler.
2. Heating furnace to heat the preform.
3. Tie rod stretches the preform in the mold.
4. Inject low-pressure air to complete the first molding.
5. Inject high-pressure air to fully form.
6. Bottle leaves from blow molding machine.
* Machine operation adopts TFT touch screen with multi languages and friendly interface. Speed, shift capacity and technical specifications can be set on the menu.* High efficiency: 2,400-2,500 BPH/cavity (500ml water bottle, 12g).
* Double blowing system. Monitoring pressure change curve of each cavity during bottle forming and providing accurate timely parameters, easier for operator to regulate technical parameters and ensure quality stability.
* Adopt cam organism and accurate mechanical arm transferring technology with high speed preform and bottle feeding, avoiding contamination.
* Cam organism controls mold opening and clamping precisely with special mold clamping boost system and firm mold shelf structure;independent control of blowing parameters of each cavity; malfunction diagnosing function; enhanced neck sealing stability; regulating blowing pressure; stretching bar controls accurate preform axial stretching and 1st / 2nd blowing controls vertical stretching; regulating of 1st / 2nd blowing precisely ensures ideal distribution of bottle wall thickness.
* Heating adopts far infrared temperature control; each heating lamp of pre-heating and regulating zone can be regulated;timely temperature monitoring system ensures technical stability and accuracy, avoiding over high temperature of outer preform wall;10-20% electrical power is saved by this heating system.
* Air recycling system may save compressed air by 30-50%.
* Technical parameters like heating temperature and blowing time can be set according to different preforms and bottle design.
* Fast mold changing (6-screw, 6-8 min for each mold) reduces stop time and increases production efficiency.
* Humanized design makes complicated industrial operation get used to habits.
* Blowing mold is made of aluminum magnesium alloy with oxidization treatment on surface to prolong mold lifespan.
* Preform infeed starwheel adopts preform block detecting device. When blocks, preform will be rejected and reset
automatically.
* Safety door is equipped with alarming device to protect operators.
2. Hopper and elevating system
* A certain amount of preforms will be stored in hopper to guarantee the continuous of producing. The preforms will be elevated to the lining device by the belt of hopper and then sent to the oven along the filling rail to be further produced.
* Once preforms are loaded into the hopper, they are supervised by the computer. The number of the loading preforms can be automatically adjusted according to the production speed.
* The output speed can be freely adjusted according to different preforms to make the number of loading preforms match up with the production speed.
* The design of rotary plastic transferring belt ensures preforms avoiding damage and contamination during the transferring.
* After being lined, preforms pass the guiding wheel to the dust moving device, then to preform seats, and then go into the oven to be heated. Preforms are heated by seven to ten layers lamps in the oven, every layer lamps can heat separately. The heating circulation of the fan in the bottom of the oven make the average temperature of the inside oven.
Features:
* The closed preform path is safe and hygienic. Ion precipitator can be added to it as needed.
* Preform storage hopper, with ultra-large capacity, which can accommodate up to 50,000 preforms.
* Splicing structure, easy to transport and disassemble with simple and elegant appearance.
* Using food-grade PP material, healthy, environment friendly and making no slag or other contaminant to the preforms.
3. Oven
Heating control
Click the menu interface, the heating setting screen appears, on which the heating tubes can be precisely controlled to stabilize the furnace temperature.
Zone 1 is the heating output setting for each layer, and the operator can set the output power of lamp tubes.
Zone 2 is the actual output of each layer of heating modules and bar-shaped bar display. The actual output of each layer of lamp tubes is equal to the set value of each layer multiplied by the initial value in zone 5. Output the percentage or the percentage of blank remaining.
Zone 3 is the control switch display of a single heating lamp. If you need to operate a single lamp, you need to click the display screen to pop up a dialog box in Zone 7 to operate a single lamp.
Zone 4 is the relevant display of heating parameters, and the heating process can be adjusted by observing the data in this zone.
Zone 5 is the related setting of heating parameters, mainly setting the range of qualified billet temperature, the percentage of the initial output of the heating lamp and the percentage of heating without billet.
Zone 6 is the setting of automatic temperature adjustment parameters. This zone is an option function zone, and you can choose whether to start it according to the actual situation.
Structure of oven
* Mediation function module: adopting the latest technology, each regulation module independently controls a group of light boxes,perfectly realizes closed-loop control, and can monitor each light tube in real time. Cooperate with temperature detection to automatically adjust the preform temperature without manual operation. The effect of heating the preform is much better than the traditional ones.
* The heating control of the infrared lamps adopts the closed loop control. After setting the temperatures of oven and preforms, the computer will automatically monitor and ensure the fluctuate of temperature within the certain value to avoid effecting production because of the different temperature between day and night.
* After being heated, preform will be checked by the automatic infrared inspector, its temperature will be shown on the computer,which make every preform has the same temperature and further ensure the stability of the blowing technique and high finished goods rate;
* Insulation ceramic board greatly improves the utilization rate of energy.
Outer lamp box
The optimized AIR heat management logic adopts a bottle-upside-down heating structure to effectively maintain the size of the bottle mouth and heat loss.The unique ceramic heat insulation structure is used to better manage the heat effectively.
* Long life: The lamp tube is more durable than other traditional mercury lamps, and the service life is less affected by switching times.
* Instant start: It is easy to start and preheat instantly to reach the maximum UV output power.
* Low temperature but high efficiency: Low temperature and high energy, stable light output, good uniformity of irradiation, and improved production efficiency.
* Safe and environment friendly: It makes less ozone emission, which is safe, environmentally friendly and energy-saving.
* Easy loading and unloading: Different groups of lamp tubes can be conveniently installed according to the height of the bottle body, which is energy-saving and convenient.
Heating oven cooling system
The streamline guide plate is used to make the air flow more effective in cooling and protecting the preform mouth.
The adjustment device has a scale indicator, which makes the equipment adjustment more convenient.
Blow off the excess temperature of the light box and the outer surface of the preform
4. Mainframe of blowing machine
After being heated in the oven, the preform will be transferred into the mold by transfer arm. The preform will be sealed by sealing seat, stretched by stretching seat and blown by low pressure air and high-pressure air (hot filling bottle will be blown by cooling air). According to different technical requirements, the mold will be cooled by cooling water if blows cold filling bottle, the mold will be heated by hot oil if blows hot filling bottle. The whole production process will be monitored by computer.
Bottle's checkup and output
After being blown, bottle will be transferred out of mold to output rail which can be connected with the air conveyor of the filling production line. Or bottle will be directly transferred on the conveyer belt to the bottle storehouse.
Working theory of bottle blowing machine
The main cam will rotate in high speed. The rotary angle will be tested by the coder on the top of the equipment and the sensor installed on the main cam. Then the information will be sent back to the computer which will send message to the solenoid valve according to the program settled by the operator. The certain action will be carried out to blow in the certain time to finish the double oriented method blowing technique during the rotary of the machine and the conforming bottles will be produced.
5. Pneumatic cylinder stretching with air recycling
* The unique quick changing device makes the replacement more convenient.
* Unique reverse buffer technology reduces impact inertia, effectively controls noise and reduces vibration
* Widened guide rails and sliders for more stable stretching motion.
6. Drive, brake and synchronization system
Setting the speed on the control panel → PCC (programmable control system) → transducer → main electric motor → gear box → belt wheel → toothed belt → speed cam and preform transfer belt wheel → oven belt wheel and bottle transfer belt wheel → preform filling wheel and bottle produced cam.
7. Special mold frame system
* The special designed mold frame system ensures the possibility of quick and accurate changing mold (6-screw).
* Mold frame with air pressure balance device makes the minimum break line when blowing bottles, which guarantee the quality of the bottles.
* The special neck sealing design reduces the pressure between preform neck and sealing to the minimum, thus the neck of preform couldn't be damaged.
8. Twice stretching system
* The equipment has the special designed twice blowing system (equipment for hot filling bottles has three times blowing system)------ pre-blowing, blowing with high pressure to finally make bottle. The blowing pressure and time of the second blowing can be adjusted. The system can guarantee the quality of finished bottle, so some bottles with complicated shapes can be blown.
* The system has the special designed pressure over loading and loss protection devices which can prevent the pneumatic parts from damaging.
* The system has the special designed stretching rail which guarantees every bottle can be stretched with the same speed and power during the stretching process.
* The cam of the manipulator adopts the design of double guide rails, and it automatically opens when taking out the bottles and preforms to avoid severe impact.
Adjustable design for easy height adjustment.
Guide rails and sliders from German Rexroth.
Bearings from German INA/F-A-G.
* The transfer of preforms and bottles are finished by transfer arm, which prevent preforms and bottles from contamination.
* The stainless steel transfer arm is processed precision, softly contacts with preform or bottle, which can avoid the scratching of the neck.
* The transfer arm has the twisting force over loading protection device which prevent the equipment from damaging when it breaks down.
10. Safe and reliable mechanical transmission
* All the important parts of the transmission come from the famous brands in Europe and American, so equipment has the reliable quality and long service life, the connection of the key transmission has the soft protection system;
* The special designed mechanical protection and automatically replace system: prefrom entering device, oven, transfer arm, rotating blower, main motor, all the above have the twisting force over loading protection system. Even though equipment breaks down, it won't be damaged;
* Torsion clutch of equipment adopts American brand which can easily adjust the grades, with automatic overloading reset functions.After eliminating resistance, the transmission system will automatically rotate by itself, all linked parts will accurately reset to the original position, without the adjusting of the operator. So all the system is convenient and quick;
* The transmission of main motor adopts German s-ew Company's frequency conversion motor, positive speed gearbox and transducer,which have characteristics of flexible non-class starter, non-class adjustment, safety and stability;
* Accurate connection between toothed belt and toothed belt wheel guarantees the accurate and safe running of every transmission part.
SIEMENS PLC controlling system
The controlling system of automatic blowing machine is made up with SIMATIC HMI (man-machine interface), Siemens industry controlling system (PLC system) and related controlling, checking and executing parts. The turn-on, turn-off and heating adjustment of equipment can be done by the man-machine interface automatically.
SIMATIC HMI(man-machine interface)operating panel contains 36 programme functional keys(28 of them with LED). Bottle blowing machine can be controlled by pressing the keys on the operational panel or by clicking the mouse(USB interface is under the bottom of the panel).
Advantages of Sunswell bottle blowing machine
* Humanization man-machine interface
* It's easy to learn the operation of man-machine interface, because there will be the breakdown position and explanation. * Every solenoid valve and cylinder can be checked to separately control every mold to blow bottles.
* Recycle the high blow air, so no need to build low pressure air station.
* With perform block inspect device, when any perform blocked, it will reject automatically and recovery automatically.
* Less time mold change time, can improve the production.
11 Discharge starwheel connecting blow molder to filler
The pneumatic part is made by F-ESTO in Germany
With the automatic failure resuming function
Automatic detection and automatic rejection of wastes function to perform safely and avoid mechanical damage
12 Filler
* The design of filling structure is reasonable and hygiene dead angle, the run of equipment is stable, it can control the material from the bottleneck, the control accuracy is within ±2mm (subject to bottle design).
* All parts are processed by CNC and machining center equipment.
* The filling system has liquid level automatic control.
* Filling valve lift is controlled by the valve elevator, after filling valve contact the bottleneck, it starts to fill.
* Bottle is conveying by the wheel in the filling part.
* The sliding sleeves of the filling valve and the bottle lifting mechanism adopt German igus corrosion-resistant and
maintenance-free bearings.
* Through the overall lifting device of the filling machine, the liquid level can be limited and adjustable
Features
* Rotary wheel fully made of stainless-steel SUS 304.
* Ring shape tank with float ball level control.
* Filling valve equips dummy cup and can do CIP circularly.
* With rotary spray ball in tank to ensure cleaning effect.
* Large flat bearing with teeth, stable and reliable performance.
* Filling method: Gravity filling
* Filling valves are made of SUS304 with reasonable structure for accurate filling.
* High-speed, high-precision liquid level, the flow rate reaches 200ml/s, and the liquid level accuracy is ≤±2mm
* Each filling valve is equipped with 2 air return channels, one of which enters the cylinder, and the other enters the vacuum chamber, which can be switched between each other during the filling process
* Bottles go up and down in the function of cam through elevator, to process filling with contact to bottle-mouth.
* Level of cylinder is controlled with float-ball.
* Filler is driven through gears inside the machine frame.
* Link-wheels in filler and capper are transported in ringed support of bottle-neck.
13 Capper
Features
* Besides the magnetic contortion variation device, there is variation dial which makes variation more easily. The benefit of this design is not only it can set the contortion, but also it makes contortion more precise and credible, and reduces inferior.
* Cap distributing chute is equipped with reverse cap stop and reverse cap pick-out mechanism.
* Cap distributing chute is equipped with a photocell switch to stop the capper when there is no cap inside the chute.
* The capper is equipped with inlet bottle detection switch.
* Centrifugal way of cap arranging is adopted to reduce damage of caps.
* A cap inspecting system is applied to control on-off of elevator.
* Magnetic constant torque capping head ensures stability and controls defective rate of capping less than 0.2%.
* Cap dropping rail equips a group of photoelectrical switch for reverse cap detecting. When lack of cap, machine will be stopped automatically.
* Bottle infeed detecting switch works with the pneumatic cylinder on cap starwheel to avoid feeding cap on no-bottle condition.
14 Specification
| No. |
System |
Name |
Brand |
Origin |
|
1
|
Transmission |
Gear Motor |
S-e-w |
Germany |
|
2
|
Servo Motor |
L-enze |
Germany |
|
3
|
Air Compressed Brake |
Steki |
Taiwan, China |
|
4
|
Torque Limiter |
Rw |
Germany |
|
5
|
Timing Belt (Seamless) |
Sit |
Italy |
|
6
|
Key Bearing |
Ina/F-A-G |
Germany |
|
7
|
Slewing Bearing |
Xreb |
Germany |
|
8
|
Limit Switch |
Schmersal |
Germany |
|
9
|
High Pressure Airway |
(0.01Um) Precision Filter |
Walker |
UK |
|
10
|
(1Um) Precision Filter |
Walker |
UK |
|
11
|
Proportional Valve |
Lanny |
Germany |
|
12
|
High Pressure Valve Unit |
Eugen Seitz |
Switzerland |
|
13
|
Safety valve |
Goetze |
Germany |
|
14
|
Dew-Point Instrument |
GE |
USA |
|
15
|
Ionic Gas |
Ionic Gas Control |
Meech |
UK |
|
16
|
Low Pressure Airway |
Stretch Cylinder |
Rexroth |
Germany |
|
17
|
Air Tube |
F-esto |
Germany |
|
18
|
Union Joint |
F-esto |
Germany |
|
19
|
Solenoid Valve |
F-esto |
Germany |
|
20
|
Filter |
F-esto |
Germany |
|
21
|
Pressure Reducing Valve |
F-esto |
Germany |
|
22
|
Heating Machine |
Heating Module |
Sunswell |
China |
|
23
|
Axial Fan |
Ziehl-Abegg |
Germany |
|
24
|
Heating Lamp |
HC |
China |
|
25
|
O-Ring |
CNEV |
China |
|
26
|
Lubrication |
Lubrication Pump |
Skf |
Germany |
|
27
|
Control |
Frequency Transformer |
D-anfoss |
Denmark |
|
28
|
PLC |
Siemens |
Germany |
|
29
|
Control Module |
Siemens |
Germany |
|
30
|
Pressure Sensor |
S-ick |
Germany |
|
31
|
Temperature Sensor |
Raytek |
USA |
|
32
|
Photoelectric Switch |
Banner |
USA |
|
33
|
Proximity Switch |
S-ick |
Germany |
|
34
|
Touch Screen |
Siemens |
Germany |
|
35
|
Low Voltage Electrical Component |
S-chneider |
France |
|
36
|
Servo control for tracking |
L-enze |
Germany |
|
37
|
Servo control for stretching |
Rexroth |
Germany |
|
38
|
Moving Parts |
Guide Rail Pair |
Rexroth |
Germany |
|
39
|
Plastic Sliding Bearing |
Igus |
Germany |
|
40
|
Wear-Resistant Ring |
Trelleborg |
Sweden |
|
41
|
Copper Base Sliding Bearing |
CSB |
China |
|
42
|
Buffer |
Ace |
USA |
|
43
|
Mold Material |
Al 6061 |
SeAH |
Korea |
Technical Parameters
| No. |
Name |
Brand |
Origin |
| 1 |
Stainless steel 304 Material of filling valve |
Nitto |
Japan |
|
2
|
Stainless steel 304
Material of rotary tray and stand of filler |
Nitto |
Japan |
|
3
|
Main motor |
S-E-W |
|
|
4
|
Sliding bearing |
Igus |
|
|
5
|
Frequency inverter |
Siemens |
|
|
6
|
Touch screen |
Siemens |
|
|
7
|
PLC |
Siemens |
|
|
8
|
Pneumatic components |
F-esto |
|
|
9
|
Photocell switch |
L-euze |
|
|
10
|
Proximity switch |
L-euze |
|
| Station Number |
10 |
| Mold Cavity Qty. |
10 |
Machine Weight
(Not inc. preform unscrambler) |
20 ton |
| Blow Molding Machine Height (m) |
3.2 |
| Preform Unscrambler Height (m) |
4.3 |
| Area Occupation (m2) |
12x10 |
| Capacity |
Based on 0.5 L |
24,000BPH |
| Bottle Size (L) |
0.25-2.0 |
| Max. Bottle Diameter (or Diagonal) (mm) |
100 |
| Max. Diameter of Holding Ring (mm) |
36 |
| Max. Bottle Height (mm) |
335 |
| Preform Material |
PET |
| Voltage |
AC380V 3PH+PE |
| Frequency |
50/60Hz |
| Installed Power (KW) |
220 |
| Working Power |
0.5L (12g) (KW) |
80.5-88 |
| Low Compressed Air Pressure (Mpa) |
0.7 |
| Inlet Compressed Air Purity |
ISO8573-1 |
| High Compressed Air Pressure (Mpa) |
3.5-4.0 |
| Inlet Compressed Air Purity |
ISO8573-1 |
| 500ml |
High Compressed Air Flow Volume (M3/Min)
(with Air Recycling) |
17.8 |
| Heating Oven Cooling |
Inlet Temperature (ºC) |
17-22 |
| Pressure (bar) |
6.0 |
| Cooling Water Flow Volume (m3/h) |
3.0 |
| pH Value |
7-8 |
| Inlet/Outlet Temperature Difference (ºC) |
8 |
| Mold Cooling |
Inlet Temperature (ºC) |
9-15 |
| Pressure (bar) |
6.0 |
| Cooling Water Flow Volume (m3/h) |
10 |
| pH Value |
7-8 |
| Inlet/Outlet Temperature Difference (ºC) |
3 |
| Station number |
Filler 50, Capper 18 |
| Rated capacity |
24,000BPH (500ml) |
| Filling type |
Gravity Filling |
| Suitable bottle |
Diameter: φ55-90, bottle height:150-290 |
| Pneumatic pressure |
0.7 MPa |
| Air consumption |
1m3/min |
| Voltage |
380V |
| Main motor power |
9Kw |
| Overall dimension (L×W×H) |
6200mm×4550mm×2700mm |
| Weight |
9500kg |
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