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Design Choices from an Industrial Packaging Blow Molding System

For a long time, manufacturers relied on the accumulator head process to create plastic drums capable of holding 15 gallons or more of liquid. Over time, they switched to the continuous extrusion system. This allowed them to manufacture “jerrycans,” which are strong and ridged plastic containers. Today, accumulator head blow molding remains a preferred manufacturing method due to its benefits.

Key Benefits of Using an Accumulator Blow Molding Machine

The increasing popularity of the accumulator machine isn’t by happenstance. Rather, it comes from the broad range of benefits that this machine provides. Below are a few examples of what this manufacturing system achieves.

  • Reduced cycle time
  • Enhanced product quality
  • Less power consumption
  • Eliminated risk of sagging parisons

The machine also helps prevents problems associated with parison sagging, which commonly occurs in lengthy extrusion processes. Using the parison problem as an example, the accumulator head blow molding method has an incredible post-cooling process. In addition, it uses significantly high material weight PE. That strengthens the melting capability. 

With these two things combined, manufacturers can achieve superior results. This process is ideal not only for smaller containers but also for large and heavy L-ring 55-gallon drums.

Design Features of the Accumulator Machine

Find out why so many manufacturers depend on this particular machine to produce stellar products. Below are just a few of the innovative design options.

Parison Configuration

The machine operator can select the location of where the parison goes. One option involves moving the mold so that it catches the parison from the extrusion head. Another option consists of moving the parison into the mold as it exits the extrusion head. Along with this, it’s possible to transfer the parison in both a horizontal and vertical position.

Due to three issues, manufacturers find it difficult to transfer parisons vertically. For one thing, while operating an accumulator blow molding machine, the extrusion head should be at the same level as the vertical mold axis. For another, there needs to be a specific distance between the head and mold for the parison to extrude correctly and completely before the mold opens. 

Verifying vertical location, distance, and the opening of the mold is what allows transfer grippers to place the parison into the cavity of the mold quickly and vertically. Here’s another issue with incorrect distance. Companies that use accumulator blow molding to produce L-ring drums would find it difficult to reach the extrusion head.

Fortunately, there are corrections for both problems.

  • Extrusion Head and Vertical Mold Axis

Depending on the design of the accumulator blow molding machine, a weak point in the vertical parison transfer layout might exist. If so, the manufacturer can convert it or have the conversion done by a reputable source. Not only will this help with the vertical transfer of parisons, but it’ll also enhance the efficiency and safety of the machine’s operations.

  • Incorrect or Inadequate Distance

As for the distance problem, one manufacturing company came up with a brilliant solution. It created a service room under the extruder’s platform. Using stairs by the mezzanine allows workers to repair or maintain the accumulator machine without any risks.

Predictive Maintenance

Proper maintenance is one of the key elements of achieving outstanding results with any accumulator machine, including the double layer blow molding machine. This includes both preventative and predictive maintenance. For preventative maintenance, experts depend on historical data and best practices whereas predictive maintenance comes from information gathered by machine operators.

Rather than perform tasks based on a set schedule, manufacturers can enhance the machine’s design. This consists of integrating maintenance tools into the machine’s programming. That’ll help them identify issues before they become serious and, therefore, minimize risks.

By using smart components, an accumulator machine will continually monitor heating bands, hydraulic pumps, utility fluids, and so on. However, they’ll also compare the machine’s operations with ideal circumstances to detect potential problems. Once the risk of failure goes beyond a set threshold, smart components send out a warning signal.

Overall, this design upgrade will help manufacturers avoid damaging the machine and extend the life of the machine.

Web-Based HMI

This accumulator machine design feature allows the manufacturer to control operations via a web-based HMI. They can perform setup functions, operate the machine, and even conduct preventative maintenance. The web-based HMI design significantly reduces the amount of time it takes to create a finished product without compromising on quality.

Also, as a customizable interface, supervisors can grant permissions based on each operator’s needs. It can even determine and control a parison’s thickness by corresponding to dynamic graphs that show head tools’ movements.

Heat Technology

The double layer blow molding machine features two layers of mineral wool that serve as insulation. That makes it easier to maintain the proper temperature required to melt plastic material. It also simplifies the various phases of the molding process. In addition, the insulation prevents heat loss. That means the machine uses less energy, which in turn, saves money.

Today’s Advanced Design Features

No matter what type and quantity of plastic containers your company makes, it’s essential to work with superior plastic materials and a cutting-edge machine. At PET All Manufacturing, Inc., we can help you select the right accumulator blow molding machine and discuss enhancing its design. We offer our customers the most advanced options available. Give us a call. One of our experts will gladly answer all your questions and assist you with the selection process.

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