Success of Japanese PET Technology in India

Ever since polyethylene terephthalate (PET) became the most accepted medium to pack a wide range of products, the consumer goods sector as well as the pharmaceutical industry got a shot in the arm. They could reach out to the target buyers with their products packed in attractive manner and longer shelf life. Simultaneously to meet the needs of the hour, the packaging industry too has made great strides on all fronts. In these progressive trends, the blow moulds manufacturer in India has played a pivotal role.

All these developments took place amid a sort of boom that the country had never seen before. It opened up new vistas for entrepreneurs to learn about PET technology and process to set up units in making preform moulds of varied cavities. Alongside, the demand for moulding machines also rose. Capitalising on this scenario, leading manufacturers of these machines from abroad made their presence felt in India.

For instance, the Japanese giant Nissei ASB Machine Company even went a step ahead by commissioning a factory at Ambernath in Maharashtra. It is one of the most modern and largest manufacturing facilities among PET processing machine manufacturers in the world. Apart from catering to the domestic market, the ASB machines manufactured here are exported too and thus earn precious foreign exchange.

These machines are in great demand for products such as edible oil, shampoo, liquor, water, mouthwash, cosmetics, detergents etc. For the items that are packed in wide mouth jars, these blow moulding machines are deemed to be the best.

However, the specific moulds for these machines must be of highest quality at par with the Japanese standards. Consequently, this has encouraged the Indian PET preform industry to master the expertise in designing and manufacturing blow moulds for ASB Machines. Reportedly, ASB has created a global impact for its machines intrinsic worth such as:

• Compact size 
• High quality bottles
• Rapid mould changeover
• Computerised memory for storage of varied moulds
• Cost & energy saving

Blow Moulding Industry in India

Although the concept of blow moulding is attributed to the Egyptians during the era of 1700 to 1600 B.C., its process was reportedly first used by the Syrians sometime in the first century B.C. It was the technique of a glass bulb on the end of a blow pipe being shaped into desired hollow forms. 

However, American S T Armstrong is credited to have patented blow moulding technique of a plastic material other than glass in 1851. It was in 1938 that the ultimate industrial application was evolved by the pioneering experiment and work of two inventors, Enoch Ferngren and William Kopitke. Meanwhile, in the mid 1930s, the British company, ICI (Imperial Chemical Industries) formulated low-density polyethylene (LDPE) for the first time that was later commercialised in 1939 and perfected in 1945 for squeeze bottles.

These developments ushered a revolution in the utility of bottles (glass and synthetic-based) as packaging material and today, these have become the common medium for filtered/distilled water, aerated beverages, milk, edible and non-edible oils, cosmetics, medicines (both in solid and liquid formats) and numerous other consumer items. This packing is based on mechanized (automatic) blow moulding machine using PET preform technology. Its impact in terms of growth could be assessed from the fact that the USA witnessed the number of plastic containers for the soft drinks shooting up within a span of 22 years (1977-1999) from a mere zero to ten billion pieces!!

In India several entrepreneurs have made a mark by designing and developing unique models of blow mould systems. These range from PET stretch blow moulding, extrusion blow moulding, reheated stretch blow moulding (RSBM) and injection stretch blow moulding (ISBM) machines among others. These machines boast of different bottling capacities as per the end user’s needs.

Rigid quality control, high standards, competitive prices and delivery alongside prompt after-sales service have lent the Indian manufacturers of automatic moulding machines an edge over their counterparts and competitors from across the world. To cite an example, the machines designed and manufactured by Noida-based Ashish Tools have been found most suitable as an integral part in a wide range of bottling systems including leading brands like the two-stage SBO, Krones Contiform, ASB Nesei, Aoki and several other models, both at home and abroad. With the worldwide acceptance of PET moulding technology as an ideal mode of bottling, the moulding industry in India is poised to reach newer heights in the coming days.

How To Choose The Right Hot Runner System?

When the decision has been made to incorporate a hot runner system into a mold, the question that promptly surfaces is as to what attributes must be taken into consideration? With the many independent suppliers in the market the types and choices of systems are often in resemblance with one system to another. In such a scenario how to opt for the right hot runner system, let’s find out.

Hot runner technology comes with diverse options. In order to accrue molding efficiencies and part quality benefits there are cases where price take precedence over application. Following are some hot runner features and supplier support aspects to consider before making a purchasing decision:

1. After Sale Service
 
In addition to sales, it is important to assure that whether the supplier offer product service, training and start-up assistance or not. These follow-ups are important for an effective installation.

2. Product Range Offerings

In order to achieve the optimum system for molding application and to maximize design flexibility, the supplier must offer an extensive nozzle range of hot tips, valve and edge gates, hot sprues, multi-tips, etc.

3. Resin Testing 

Check out for fully equipped resin testing or R&D facility in order to assist the OEM or mold maker in choosing the best hot runner system type. Furthermore, there should be a balance of resin flow, channel sizing and various other design capabilities to produce a thermally balanced hot runner system. In such a system runners are large enough to give a relatively small pressure drop through the system without causing too much residence time while casting an injection mould.

4. Ease of Maintenance 

At last, ease of maintenance defines the level of system’s sustenance. Your runner installation decision should answer the following questions:

• Can the gates be cleaned in the machine? 
• Can wear items such as nozzle tips, thermocouples and heater bands be replaced without removing the mold from the machine? 
• Can the valve stems in valve-gated systems be adjusted or replaced in the molding machine? 

All these tips are helpful while installing a hot runner system to enhance injection moulding processes. Use of a hot runner system can increase overall molding efficiency by reducing cycle time (easy maintenance), energy and material costs.

Hot Runner Technology In Molding

An introduction

The Hot Runner Technology (HRT) is an advanced and applied technology. The technique is lucrative more in injection molding. Certain providers of hot runner system noida have contributed to a great deal in optimization of product quality.

The hot runner technology lends a great deal of efficiency by increasing production, utilizing raw material, being energy effective and cutting down on the cost of production. Read on to find out how the hot runner technology in injection mold has been beneficial to the pet perform manufacturers in India. Several design instances technology in injection mold has supported the suitability of hot runner system.

It is important to note that the technology is applicable to the injection molds alone and not to all kind of plastic molds. However, hot runner system is applicable for a few types of thermoplastics.

Advantages of HRT

- Materials cost effective— no need to regrind or reprocess.  Less costly material  cost
- Lowering down energy costs, short and cycle times as there is no need to wait for   runners to cool down
- The small size of machines and reduced shot volume into runners
- The runners need not to be separated from the parts, the processing is automated Gates are stationed at the best of the strategic position for optimized economical design
- No runners to remove or regrind, thus no secondary work is needed
- Lower injection pressures
- Less clamping pressure
- Reduced cooling time
- Shot size reduced
- Cleaner and well maintained molding process
- Consistently constant  heat within the cavity

Disadvantages of HRT

- Hot runner molds are more complex and expensive to build than cold runner molds
- Escalated initial start-up costs than for cold runner systems
- Jeopardize sensitivity of materials causing thermal damage
- Extended temperature control is required which leads to delay in mold processing
- Higher maintenance costs which is more susceptible to breakdowns and heating   element failure

What Happened When Mould Making Met System Engineering?

By many, system engineering and mould making are referred to as two sides of the same coin. The discipline of applied science lets students invent new items and techniques for doing a particular job. Likewise, invention is the heart and soul of mouldmaking. Hence, there has to be some connection between mouldmaking and system engineering. Read on to explore...

An example to explain the close affair between systemized engineering and mouldmaking

At present, the market for trim panels that are used in a car’s interior is large.  Use of a high-quality injection mould is done to manufacture the best-in-class automotive trim panels. The plasticised trim panels for a car’s interior have to be both stylish and functional. Surfaces of interior automotive trim panels have to be appealing as finished panels become the Unique Selling Point (USP) for most cars.

 In addition, devotion as well as attention is given to a car’s instrument panel, dashboard, headliner, inner door panels, etc.  The trim panels have to be relentlessly redesigned to introduce freshness in a car’s interior. The mouldmaking for trim panels is complex, speedy and innovative.  Many trim panel mouldmakers bank upon the concepts of the discipline for being:-

•    Innovative
•    Fast paced
•    Able to carry out complex detailing

Mould designers who are and aren’t in support of system engineering

Most mouldmakers believe that system engineering must be left to the Original Equipment Manufacturers (OEMs). Those mouldmakers who don’t want to tweak their working process never endorse system engineering.

Nevertheless, a few forward-thinking mouldmakers opine that a small, significant portion of system engineering will play a pivotal role in the overall business. The discipline helps in making the overall process of mouldmaking highly innovative. Further, every contemporary mould designer believes that the engineering principles help in expounding the scope of moulding. Also, mould designers require the discipline’s principles to manufacture injection-moulded parts in no time.

Let’s clear the air between systemized integration and engineering

Mixing the principles of system integration and engineering helps improve communication, thus, resulting in excellent mould manufacturing.  Let’s clear the difference of the meanings of the two terms.

•    Systemized integration

System integration helps in connecting actual/physical assets of a company. The process joins the entire factory floor system – machining, testing, assembly as well as packaging – that’s used in manufacturing. System integration is defined as the physical counterpart of systemized engineering.

•    Systemized engineering

The discipline is multifaceted. Mouldmakers use the engineering discipline to determine a client’s requirements in the very beginning (while designing development cycle) of the process.  Systemized technology helps mould designers understand requirements (technical as well as business) of a client.

The joining of systemized engineering along with integration is strategic. Blending the two approaches helps mouldmakers design high-quality injection moulds for ASB Machines and other specialized equipment.

Joining both the concepts with mouldmaking proves to lessen the complexity of the process. A moulding process’ complexity rises whenever technological shifts take place. Combining the principles of engineering and integration helps mouldmakers grapple with such dramatic technological shifts.

What Happened When Mould Making Met System Engineering?

By many, system engineering and mould making are referred to as two sides of the same coin. The discipline of applied science lets students invent new items and techniques for doing a particular job. Likewise, invention is the heart and soul of mouldmaking. Hence, there has to be some connection between mouldmaking and system engineering. Read on to explore...

An example to explain the close affair between systemized engineering and mouldmaking

At present, the market for trim panels that are used in a car’s interior is large.  Use of a high-quality injection mould is done to manufacture the best-in-class automotive trim panels. The plasticised trim panels for a car’s interior have to be both stylish and functional. Surfaces of interior automotive trim panels have to be appealing as finished panels become the Unique Selling Point (USP) for most cars.

 In addition, devotion as well as attention is given to a car’s instrument panel, dashboard, headliner, inner door panels, etc.  The trim panels have to be relentlessly redesigned to introduce freshness in a car’s interior. The mouldmaking for trim panels is complex, speedy and innovative.  Many trim panel mouldmakers bank upon the concepts of the discipline for being:-

•    Innovative
•    Fast paced
•    Able to carry out complex detailing

Mould designers who are and aren’t in support of system engineering

Most mouldmakers believe that system engineering must be left to the Original Equipment Manufacturers (OEMs). Those mouldmakers who don’t want to tweak their working process never endorse system engineering.

Nevertheless, a few forward-thinking mouldmakers opine that a small, significant portion of system engineering will play a pivotal role in the overall business. The discipline helps in making the overall process of mouldmaking highly innovative. Further, every contemporary mould designer believes that the engineering principles help in expounding the scope of moulding. Also, mould designers require the discipline’s principles to manufacture injection-moulded parts in no time.

Let’s clear the air between systemized integration and engineering

Mixing the principles of system integration and engineering helps improve communication, thus, resulting in excellent mould manufacturing.  Let’s clear the difference of the meanings of the two terms.

•    Systemized integration

System integration helps in connecting actual/physical assets of a company. The process joins the entire factory floor system – machining, testing, assembly as well as packaging – that’s used in manufacturing. System integration is defined as the physical counterpart of systemized engineering.

•    Systemized engineering

The discipline is multifaceted. Mouldmakers use the engineering discipline to determine a client’s requirements in the very beginning (while designing development cycle) of the process.  Systemized technology helps mould designers understand requirements (technical as well as business) of a client.

The joining of systemized engineering along with integration is strategic. Blending the two approaches helps mouldmakers design high-quality injection moulds for ASB Machines and other specialized equipment.

Joining both the concepts with mouldmaking proves to lessen the complexity of the process. A moulding process’ complexity rises whenever technological shifts take place. Combining the principles of engineering and integration helps mouldmakers grapple with such dramatic technological shifts.

Future Of Injection Moulding Is Metal Injection Moulding

In the previous decade, both large and small injection moulding companies have witnessed shifting sands in the global business environment. Changes that tweak the moulding business environment are cost pressure from clients and relentless efforts to improve the productivity. Presently, more and more companies invest in cutting-edge tooling, automotive equipment and moulding machinery to gain competitive edge. Companies are hailing innovative, fresh assembly solutions at the moulding phase.

One such innovative moulding method is Metal Injection Moulding (MIM) that was introduced in the ‘70s. The beginning of MIM was a trifle shaky as the technology underwent several years of de-bugging. However, while ushering the 21st century, several moulding experts used the technology for overcoming their economic woes. 

Reasons that point MIM to be the future

•     The technique has a market of $ 1 billion per annum
•     The Compound Annual Growth Rate (CAGR) of the technique is slated to be 20 percent
•     Such an exceptional growth of the technology is due to its cost-saving nature
•     MIM cuts down the wastage of raw materials, which is common in conventional moulding
•     The cycle time of MIM is reduced by 50 percent from that found in conventional moulding

MIM has become the primary growth factor for many technical players, belonging to firearm and medical sectors.  Also, the technology is accepted by Pet Preform Manufacturers in India churning out pet bottle moulds.




Which all sectors cherish MIM technique?

•  Several firearm manufacturers herald the technology for manufacturing high volumes of sophisticated  weaponry. The technology saves oodles of resources that could be otherwise spent over high-priced gunsmithing and machining.
•  Medical Equipment Original Equipment Manufacturers (OEMs) are utilizing the wonders of MIM   technique owing to its capacity to minimize cost.

The socioeconomic and microeconomic benefits of MIM make it an ideal solution to offer more value to clients.

For More Info Visit Us : www.ashishtools.co.in