SIPA has launched the XTREME Sincro, a preform compression molding system with a high-speed stretch-blow molding unit, at BrauBeviale in Nuremberg, Germany in November 2014.
The injection- compression- stretch-blow molding (ICSBM) system, “combines the flexibility of two-stage systems with the convenience of single-stage system”, says GM Enrico Gribaudo.
“We set out to create the ideal production plant,” he says.
“One that is compact, flexible and easy to operate; which has very low energy consumption; which treats the polyethylene terephthalate (PET) as gently as possible to keep material highest quality; which provides perfect product handling without damaging the preforms in any way and which produces bottles with extraordinary performance, but which are lighter than anything available on the market thus reducing the amount of PET used.”
The project is realized with the contribution of the LIFE financial instrument of the European Union, which part of an overall program to stimulate technologies that will help industry save energy and reduce emissions of carbon dioxide.
Preforms are 10% lighter
With the system, it is possible to produce preforms that are up to 10% lighter than even the lightest preform produced by conventional injection molding—but without losing any key properties.
More weight can be shaved off the body and base of the preform than ever before.
Whereas until recently, the maximum length-to-wall thickness ratio (L/t) of a preform was little more than 45, SIPA’s XTREME technology makes an L/t ratio of 80 a commercial reality.
Injection-compression molding overcomes the issue of filling molds with very thin walls, by having the molds slightly open when injection starts, and then closing them as dosing finishes.
This means lower injection pressure can be used, lower clamp force is needed (which has the additional benefit of extending mold life), and there is less stress on the melt, which means acetaldehyde (AA) levels are reduced, and resin intrinsic viscosity (IV) falls less.
It is now possible to produce preforms with bases thinner than ever before.
Full integration with bottle blowing
The versatile system shortens product changeover times with higher preform quality, says the company.
The system reportedly fits integrated preform molding and blowing operations with its rotary configuration and pneumatic actions.
In the XTREME Sincro, it is directly coupled to an SFR EVO3 next-generation rotary stretch-blow molding unit.
SIPA says EVO3 systems are faster, more versatile, and run even more efficiently than their predecessors.
Features include new designs in the clamp unit and in the cams that help the SFR EVO3 achieve a maximum output rate of 2250 bottles per hour per cavity, putting it on the front line of the grid with the competition.
Its new, compact blowing valve block has 35% less dead air volume.
Reduced energy consumption
The XTREME injection-compression system uses lower temperatures than an injection molding system, reducing energy consumption of around 10% in that section alone.
There is no need on the XTREME Sincro to cool the preforms immediately after they are molded, with reduced need to reheat them just before blowing.
Conventional ovens with infrared heaters are replaced by small ovens that use highly efficient induction heating that is directed only at the areas of the preforms just below the neck.
Fast mold change
Just like the XTREME preform molding system, the SFR EVO3 has a new standard mold changeover system that is quick and easy to use.
It is also much easier to convert from production of cold-fill to hot-fill containers.
This is because, while the heating circuit remains in the shell holder, the cooling circuit is now built into the cavity.
A simple cavity change is required to switch from production of one type of container to another, while the shell holders remain in place.
