Compression Blow Forming for plastic containers

CBF
Compression Blow Forming for the DairyIndustry
Superior Quality Containers For The DAIRY Industry
SUPERIOR NECK QUALITY
AND CONSISTENCY
Improved sealing performance, higher
consistency and repeatability of all bottle
specifications.
SUPERIOR CONTAINER
PROPERTIES
7,0
6,0
Thanks to a fully integrated quality
control vision system, CBF ensures full
compliance with specifications for all
produced bottles.
5,0
4,0
Upper Spec
Limit
3,0
2,0
1,0
Process
distribution
0,0
Superior sustainability and purity due to
lower melt temperature.
Higher consistency and repeatability of all
bottle specifications, delivering the highest
performance levels.
100% PERFECT BOTTLES
Mean
Lower Spec
Limit
SUPERIOR PROCESS QUALITY
88
,5
9
9,51
0
10,5
Weight [g] Normal distribution
X ray photo of a bottle
NO GATE
Superior performance
against stress
cracking & improved
product appearance.
In recent years the DAIRY market has shown
clear signs of strong worldwide growth. SACMI,
which has long been active in this sector, is
now strengthening its presence and extending
its already-comprehensive range of technical
solutions thanks to the introduction of CBF
technology. CBF (Compression Blow Forming)
machines constitute the technological link that
completes the SACMI solution range for the
DAIRY industry. This includes complete filling
lines for dairy products, the widely acclaimed
range of thermoforming machines and fully
tested and approved end-of-line solutions.
CBF machines reinforce SACMI’s presence
in a highly strategic market segment and
represent clear evidence of SACMI Group’s
renewed commitment to leading this segment
by introducing innovative technologies.
Technical content on this innovative process
Compression Blow Forming
State-of-the-art technology
Total cost of the bottle
Superior Bottle Quality
• Higher efficiency
• CBF technology reduces variability, improving
tolerances and statistical capability
Key process factors
CBF (Compression Blow Forming) is a unique
combination of compression molding and blow
forming. From resin to bottle in one single
rotary station: the process begins with the resin
being introduced into a continuously operating
extruder. The continuous extruder itself provides
a constant supply of molten resin which is cut
into precisely pre-sized pellets which are then
inserted into an open compression mold. This
compression cycle molds the preform to have
exactly the same weight as the final container.
The preform is temperature controlled to provide
the best blow process properties. The blow mold
is then activated and the preform is blown into
the final desired shape without requiring any
trimming, thus dramatically reducing scrap.
The container is then transferred by a positive
control system to the exit conveyor and during
this part of the process leak detection as well
as visual quality control is carried out on every
single container. CBF is a continuous process
and allows for maximum machine compactness
and fully integrated quality control. From resin
to bottle with a single, compact and highly
controlled unit: CBF is a game-changing
technology for the dairy industry.
The competitive advantages of an innovative technology
• Lower start-up time
• Lighter bottle with improved
mechanical properties
• Reduced labour requirements
• Less floor space
• Highly repetitive manufacturing process
delivering superior consistency
• No hot-runner on extrusion system
• No gate, no welding lines
• Zero resin scrap during production
Sustainability
• Improved sustainability and purity due to
lower melt temperature
• Lowest power consumption in the industry
• Lower scrap rate during production
• Less material wastage during color change
find out more about CBF
GAME-CHANGING TECHNOLOGY FOR PLASTIC CONTAINERS
PROCESS
Modular tool
One continuous process
to manufacture bottles
straight from pellets.
4
designed for maximum flexibility
3
Blow
Positive control
of the bottle
Stretch
Total quality control
performed on each bottle produced
5
Moulding
bottle vision system
2
Preform
compression
1
Pellet insertion
and bottle removal
leak test
Sacmi product development lab
100% perfect bottles
The advantages of a partner with development and testing skills
Case studies
Case Study - Summary Data
nominal capacity
100 ml
In the Closures and Containers LAB, the CBF-LAB provides all customers with complete development of
dairy packaging solutions, from the initial idea to final testing and start up on the line:
resin
HDPE
• 3D modelling, rendering and mock up, container prototyping
master
none
• Material and additive testing and characterization (DSC, DMA, crystallinity, viscosity)
overall weight
4.7 g
• Container sizing (optical, CMM, thickness, statistical analysis)
bottle weight ST. Dev
0.02 g
bottle weight range
± 0.06 g
bottle height
89 mm
bottle diameter
43 mm
mean body thickness
0.4 mm
top load resistance
70 N
max top load resistance
> 100 N
• Container performance (mechanical performance, sealing performance, OTR , WVTR)
Case Study - Summary Data
FINISH & CLOSURE
WITH ALUMINIUM FOIL SEAL
FINISH FOR
ALUMINIUM FOIL SEAL
FINISH & CLOSURE
WITH INTERNAL PLUG SEAL
FINISH & CLOSURE SNAP-ON
WITH INTERNAL PLUG SEAL
nominal capacity
350 ml
resin
HDPE
master
none
overall weight
20.7 g
bottle weight ST. Dev
0.02 g
bottle weight range
± 0.06 g
bottle height
170 mm
bottle diameter
62 mm
mean body thickness
0.55 mm
top load resistance
150 N
max top load resistance
> 200 N
A wide range of forms
The huge potential of CBF
The CBF range of machines covers a broad variety
of products that respond to the demands of today’s
DAIRY market. This innovative technology allows
producers to manufacture all the most commonly
used liquid yogurt and single-serve probiotic
containers while maintaining excellent product
quality standards. CBF aIso creates plenty of
opportunities to make the container lighter.
Moreover, CBF provides competitive manufacturing
solutions for higher-volume bottles, such as
in the fresh milk industry. Another interesting
field of application for this technology is the
yogurt industry since CBF machines can also
produce wide-mouth containers suitable, for
example, for desserts.
CBF is the ideal solution for container
manufacturers who, now more than ever, are
looking for an optimum combination of key
factors such as high output rates and flexibility.
Absolute container quality is made possible by the
numerous control devices integrated inside the
machine and can be combined with outstanding
container lightness without modifying mechanical
properties.
Moreover, CBF offers a perfect response to
the needs of the DAIRY market as all available
resins can be processed on this technology. CBF
machines offer the best response to market needs
and can handle even the broadest output and/or
container requirements.
CHINA
RUSSIA
28 Sacmi Mosca
592
Laeis China Beijing Office
Italiansped
Laeis (Dalian) Trading
Sacmi Imola Moscow Representative Office
Sacmi Hong Kong
Italiansped
GERMANY
Sacmi Machinery (Foshan Nanhai)
Sacmi Deutschland
Sacmi Hong Kong Foshan Commercial Office
Sama Maschinenbau
Sacmi (Changshu) Machinery Equipment
Riedhammer
Sacmi (Shanghai) Machinery Equipment
Alpha Ceramics
Sacmi Machinery (Foshan Nanhai) Zibo Branch
Sacmi (Jiajiang) Representative Office
Sacmi (Gaoan) Representative Office
POLAND
LUXEMBOURG
71 Laeis
UNITED
KINGDOM 22
237
Surface Inspection
09/2016
Sacmi machines and plants for dairy containers:
know-how and certified solutions
13 Sacmi Polska
24
TURKEY
Sacmi Istanbul
KOREA
2 Sacmi Machinery Korea
IRAN
27 Sacmi Iran Sazeh Ceramic
& Material Iranian
Sacmi Molds & Dies Iran
SPAIN
Sacmi Iberica 88
50
UNITED STATES
Sacmi USA - Hayes
Sacmi Molds & Dies USA
Carle & Montanari USA
JAPAN
4 Riedhammer Japan
PORTUGAL
Sacmi Portugal 7
FRANCE
Sacmi West Europe 13
EGYPT
Sacmi Molds &
4 Dies Egypt
NORTH AFRICA
Sacmi N.W.C. Africa 2
ITALY
Sacmi Imola
Sacmi Service
Sacmi Forni
COSMEC
Sacmi Molds & Dies
Nuova Sima
Keratech
Gaiotto
IN.TE.SA.
Sacmi Carpmec
Decodigit
Sacmi Filling - Benco Pack
Sacmi Verona - Sacmi Labelling
Sacmi Packaging
Pet Projecta
Carle & Montanari - Opm
CMFima
Iprel Progetti
Italiansped
Protesa
Sacmi Impianti
2
4
UNITED
ARAB
EMIRATES
Sacmi Middle East
2
SINGAPORE
Sacmi Singapore
1531
MEXICO
Sacmi de Mexico 99
Sacmi Moldes Ceramicos Mexico
Sacmi Beverage de Mexico
Sacmi de Mexico Division Logistica
INDONESIA
47 Sacmi Indonesia
PT. Molds & Dies Indonesia
SOUTH AFRICA
Sacmi South Africa
112
VENEZUELA
Sacmi Beverage Venezuela
BRAZIL
60 Sacmi do Brazil Indústrial e Comércio
THAILAND
Sacmi Thailand
19
2
5
VIETNAM
Sacmi Vietnam
ARGENTINA
2 Sacmi Impianti Argentina
INDIA
Sacmi Impianti India
Sacmi Engineering (India)
Sacmi Impianti India Morbi Warehouse
CBF technology and products have already been chosen by customers
in the biggest dairy markets worldwide: USA, CHINA and INDIA.
SACMI is a multinational cooperative and the worldleading designer, builder and distributor of plant
engineering solutions in the ceramics, beverage
& packaging, food & pharma, automation and
service industries. The Group is present in no less
than 30 countries and consists of 80 companies.
The SACMI network provides advanced after sales
service thanks to its far-reaching web of branches and
assistance centres, located on all the main markets;
there is also an optional Teleservice that can be
used with all our plant solutions. The latter ensures
customers can count not only on a fast, efficient
spare parts warehouse but also on remote diagnostic
services where specialised SACMI technicians
work alongside the customer to analyse individual
machines and find solutions to any production issues.
The
Sacmi
Group’s
technological/market
leadership position within its various businesses
areas, not to mention the Group’s financial solidity,
provides customers with production effectiveness
and efficiency they can count on, achievement of
expected results and a fast return on investment.
SACMI IMOLA S.C. Via Selice Provinciale, 17/A - 40026 Imola BO Italy
Tel. +39 0542 607111 - Fax +39 0542 642354
mail: [email protected] - [email protected]
www.sacmi.com
Sacmi reserves the right to introduce changes without notice