Extrusion blow molding

with Eastman copolyesters

Extrusion blow molding
with Eastman copolyesters

Contents
Extrusion blow molding 3

Drying copolyesters 3

Drying equipment 5

Extruder 8

Screw design 8

Head 8

Die tooling selection 8

Typical EBM processing temperature ranges for Eastar™ copolyesters 9

Extruder setup 9

Typical preparation, start-up, line-out, and shutdown procedures

for extruding Eastar amorphous copolyesters 11

Typical preparation, start-up, line-out, and shutdown procedures

for Eastar™ EB001 crystalline copolyester 12

Regrind 12

Parison cutting 12

Parison programming 13

Container and mold design for Eastar™ copolyesters 13

Eastman manufactures multiple grades Extrusion blow molding
of copolyesters for extrusion blow This publication contains information regarding the
molding (EBM) applications. processing of Eastman copolyesters by continuous and
intermittent extrusion blow molding. Primary processing
Eastar™ copolyesters EB062, 6763, and GN077 are equipment includes commercial shuttle-press and wheel-
amorphous thermoplastic polyesters of the PET machine blow molding machines using the blow-pin method
(polyethylene terephthalate) family. Eastman of thread-finish calibration and trimming, plus reciprocating
Tritan™ copolyester TX1800 is designed for higher- screw and accumulator head machines for larger containers.
Generally, machines set up to process polyvinyl chloride
temperature applications and can be used in some (PVC) and polycarbonate (PC) resins have been found to be
hot-fill applications. Eastar EB001 is a higher-IV, satisfactory for processing Eastman copolyesters. Contact
crystallized material that meets The Association of Eastman Technical Service for specific advice on optimizing
Plastics Recyclers (APR) critical guidance for a the processing setup for a particular application.

material code of 1 . All of these materials were The following information is recommended as a guide and is
designed to meet the need for a clear extrusion blow based on internal experience as well as field trials with Eastar
copolyester resins. Most applications should fall within the
molding polyester for packaging and other applications.
boundaries of the recommendations in this publication. Your
Eastar copolyesters for extrusion blow molding actual optimum processing conditions may, in some cases,
be outside the range of recommendations of this guide.
are clear thermoplastic polymers with a glass
transition temperature (Tg) of approximately
80°–84°C (176°–183°F). They are high-viscosity Drying copolyesters
resins requiring low-work-input (low-shear) extruder Drying is an absolute necessity to prepare polyester resins
screws as well as nonrestrictive die, mandrel, and for processing.
head tooling for the best extrusion blow molding All polyester resins readily absorb moisture. Polymer
processing. Applications for Eastman copolyesters dryers are used to dry the pellets prior to processing in
the extrusion blow molding machine. If pellets are not dried
include extrusion blow molded containers and
to the recommended level of dryness, the moisture will
extruded film and sheet. Tritan offers a Tg of 110°C react (hydrolyze) with the molten polymer at processing
(230°F), making it ideal for hot-fill applications up temperatures. This will result in a loss of molecular weight.
to 100°C depending on part design and thickness. This loss leads to lowered physical properties, such as
Tritan TX1800 is also dishwasher safe in extrusion reduced melt, tensile, and impact strengths. Check with the
dryer manufacturer or Eastman Technical Service for proper
blow molding applications up to 100°C. These
setup, operation, and troubleshooting.
materials offer the excellent gloss, clarity, and
sparkle needed for clear, molded containers or other
hollow articles. Extrusion blow molded containers
molded from Eastman copolyesters are not
suggested for use as pressurized containers, such
as those used for carbonated beverages.

3
Figure 1. Typical desiccant dryer

Regeneration
Regeneration air filter
blower

Process Regeneration
heater heater

Regeneration
temperature
control

Desiccant
carousel

Process
temperature
Return Return monitor
air filter air filter and control

Figure 2. Desiccant wheel dryer

4
1
Process Process
RTD protection RTD 6 Regeneration
Process 7 blower
heater box High-temp.
shutoff

Regeneration
air filter
High-temp.
shutoff
Regeneration
5 heater

Regeneration
RTD

Hopper
Desiccant
2 wheel
3

Regeneration
Return outlet RTD
air filter Return
air RTD
Aftercooler

n PROCESS
Process n COOLING
blower
n REGENERATION

DRYER OPTIONS 4—Phase rotation protection

1—Setback temperature 5—Precooler
2—Dew point monitor/control 6—Alarm bell
3—Process filter status 7—Alarm light

4
Drying equipment It is also important to maintain an air temperature of at least
205°C (400°F) in the regeneration loop of desiccant dryers.
Multibed desiccant dryers (Figure 1) The regeneration loop is a separate system from the process
These dryers have two or more desiccant beds and are used loop, so the presence of hot air in the process loop does not
to properly dry the resin. Dryers with three or four beds guarantee that the regeneration loop is functioning.
typically have shorter start-up times because of quicker
bed regeneration. Desiccant dryers are available from many The importance of dry air
suppliers. Work with your dryer vendor to select the With desiccant bed regeneration drying systems, dry air
optimum dryer for the molding job. Locating a drying hopper comes from the desiccant beds in the closed-air circulation
on the feed throat of the molding machine is preferred. loop of the dryer/hopper system. Desiccant beds must be
However, a remote system with closed-loop pellet transfer heated and regenerated before they can dry incoming
works well too. Planning should include consideration for process air. After regeneration, it is beneficial to cool down
throughput rate, ease of maintenance, reliability, and low the regenerated bed with closed-loop (previously dried) air
variability of the four elements necessary for proper drying as opposed to ambient air.
(drying temperature, drying time, dryness of air, and airflow)
Process air returning from the top of the pellet hopper is
These four elements are discussed in the section “Elements
filtered before it is blown through the desiccant bed and
necessary for proper drying.”
onto the heater and hopper. Dryers used for amorphous
copolyesters should be equipped with aftercoolers to cool
Other dryer types the returning process air. Air temperature should be below
Polymer drying systems other than the traditional twin- 65°C (150°F) to increase the desiccant’s affinity for moisture,
tower and carousel regenerating desiccant designs are thus improving efficiency.
available. For example, compressed air resin drying systems The desiccant in the beds is typically a very fine claylike
and desiccant wheel-type dryers (Figure 2) are a viable material in pea-size pellets. It slowly loses its usefulness and
option for drying copolyesters. Vacuum dryers are not must be replaced periodically—usually about once a year.
recommended for use with Eastar copolyesters. Many Use of plastic with a high dust content (such as regrind) or
dryer manufacturers are familiar with Eastman materials materials containing certain additives will reduce the life of
and can provide guidance on selecting the right size and the desiccant by coating the pellets or saturating them with
type of dryer for these resins. a nonvolatile material. Good filter maintenance can help
extend the life of the bed and the heater elements.
Elements necessary for proper drying Air dryness can be checked by dew point meters, either
Drying temperature portable or installed in-line in the dryer. These meters give
Air circulating through the hopper is heated by the process a direct reading of the dew point of the air tested. When the
heaters. The air temperature should be measured at the inlet dryer has rotating beds, the meter must run long enough for
to the hopper and controlled at the recommended drying all beds to be checked. Each bed can normally be online for
temperature for the resin. Exceeding this temperature can 20 to 40 minutes or longer; a new bed should rotate into
cause premature softening or melting of pellets to the point position before the dew point rises above –20°C (–4°F).
of sticking together, causing failure to feed freely to the (Also see the discussion on “Moisture measurement.”)
bottom of the dryer for unloading. Drying at temperatures
Caution: Once pellets are dried, they must not be exposed to
below the recommended set point will result in inadequate
moist air in conveying or at the machine hopper. Otherwise,
drying. When the controlling thermocouple is located away
the pellets may reabsorb enough moisture to lower physical
from the hopper, the set point may need to be raised to
properties, reduce melt strength, or create bubbles in the
offset heat loss from the air during transport to maintain the
extrudate.
desired hopper inlet temperature. Check the temperature
over several cycles of the process heater. If the actual
temperature overshoots the set point, adjust the set point
accordingly to avoid overriding temperatures. Drying
temperature should be held constant within ±3°C (±5°F).
Insulated supply hoses and hoppers make drying much more
effective and energy efficient.

5
Airflow Choosing the hopper size is critical; only when the hopper
The usual airflow rate requirement for drying is 0.06 cubic size is adequate for the rate of processing will the proper
meters of hot, dry air per minute for each kilogram of residence time in the hopper be possible. For example, if a
material processed per hour (0.06 m3/min per kg/h) or 454-g (1-lb) part is being molded at a 1-minute cycle, then
1 cubic foot of hot dry air per minute for each pound of 27.2 kg (60 lb) of dry material will be needed each hour.
material processed per hour (1 cfm per lb/h). For example, If 6 hours is required for drying, then at least 164 kg (360 lb)
if 109 kg (240 lb) of material is used per hour, airflow should of material must be in the hopper continuously [27.2 kg/h
be at least 6.7 m3/min (240 cfm). The minimum airflow to x 6 h]. The hopper should be designed so that plastic pellets
ensure good air distribution is typically 2.8 m3/min (100 cfm) in all parts of the hopper will move uniformly downward as
for smaller dryers. material is removed from the bottom. Funneling pellets
down the center of the hopper while pellets near the outside
Airflow can be checked by in-line airflow meters, by portable
move more slowly will result in inadequate drying due to less
meters, or much less accurately by disconnecting a hose
residence time in the hopper.
going into the hopper and feeling the airflow—basically a
yes/no on airflow. In routine operation, drying time is maintained by keeping
the hopper full. If the hopper level is allowed to run low,
If there are dust filters in the circulation loop, they should
residence time of the plastic in the hopper will be too short
be cleaned or replaced periodically to avoid reduction in the
and the material will not be adequately dried. For this reason,
airflow rate.
and to compensate for less-than-perfect plug flow through
Regrind with high levels of flakes and fines can reduce the the dryer, the hopper should be larger than the exact size
normal airflow and efficiency of the drying system. Frequent calculated. Also, addition of regrind decreases the bulk
filter cleaning or replacement may be necessary. density of the resin, thus requiring a larger dryer hopper to
achieve the required residence time.
Suggested drying conditions for Eastar
amorphous and crystalline materials Moisture measurement
Actual drying time is dependent on initial resin moisture level Dew point meters measure only the dryness of the air, not
and efficiency of the drying system. Generally, 6 hours of the dryness of the plastic pellets in the hopper. Use of the
drying time is adequate. However, higher pellet moisture and/ dew point meter along with measurements of temperature,
or inefficient drying systems can require a longer drying time. airflow, and time can give an accurate indication of whether
the plastic pellets are being dried properly.
Pellets to be dried need to be in the hopper at the conditions
shown on the data sheets for each specific polymer. If the A moisture level in the range of 0.05% (500 ppm) to 0.02%
dryer is turned on from a cold start, it must warm up to the (200 ppm) or less is desired for amorphous copolyester.
proper temperature and the dew point of the air must be For crystalline materials (EB001) a moisture level in the range
reduced to –20°C (–4°F) or below before drying time can be of 0.005% (50 ppm) to 0.0030% (30 ppm) or less is
counted. Check dryer manual for recommended warm-up recommended. This can be determined using analytical
times to allow the desiccant to regenerate and the pellets to means such as Karl Fischer titration method or weight loss
reach the desired drying temperature. See Table 1 for typical moisture meters that measure the moisture inside pellets.
drying conditions. These meters can give a good indication of the effectiveness
of the drying system in reducing the moisture level in the
plastic pellets.

Table 1. Typical drying conditions

Amorphous Eastar copolyesters

(6763, GN046, GN077, and EB062) Tritan copolyester TX1800 Eastar crystalline EB001
Temperature 65°C ± 3°C (150°F ± 5°F) 88°C ± 3°C (190°F ± 5°F) 150°C ± 3°C (300°F ± 5°F)

Time 6 h, minimum 6 h, minimum 6 h, minimum

Dew point –30° to –40°F, minimum –40°F –40°F

Airflow 1 cfm/lb/h (0.06 m3/min/kg/h) 1 cfm/lb/h (0.06 m3/min/kg/h) 1 cfm/lb/h (0.06 m3/min/kg/h)

Note: These conditions are normally adequate to achieve a polymer pellet moisture level that minimizes degradation of the polymer during processing.
The target polymer moisture level for Tritan and amorphous Eastar resin is less than 500 ppm or 0.05% at the time of melting. The target polymer
moisture level for crystalline EB001 materials is less than 50 ppm or 0.005% at the time of melting. (See “Moisture measurement” section.)

6
Loss-in-weight moisture analyzers are commercially to a –40 dew point when they fail, meaning they can show
available. They offer results in minutes and use no hazardous an acceptable dew point when they are not actually working.
chemicals to dispose of. Check with Eastman Technical Independent verification of process-air dew point with a
Service for specific recommendations. Some models can be portable dew point meter is highly recommended.
purchased with the algorithm for most Eastman resins, along
with many others, already loaded. Common desiccant dryer problems
• Poor airflow caused by clogged filters
Best practice recommendations • A
 ir passing through the middle of the hopper load rather
than dispersing through the pellets caused by underfilled
If on-site moisture analysis is available, it is a good idea to
hopper
check the moisture level of the incoming pellets before
drying. An unusually high beginning moisture level may make • S upply/return dry-air lines leak allowing ambient wet air
it necessary to adjust drying time and temperature. to contaminate dry air.
• A
 mbient, wet air contamination through loader on top of
Check the moisture level of the pellets after drying at the
hopper or other air leaks
extruder hopper or feed throat to ensure the recommended
• L ack of cooldown on air returning to the desiccant bed in
moisture level is within range for that particular material.
absorption process. Air should be cooled below 65°C
(150°F) to increase the desiccant’s affinity for moisture,
Dryer troubleshooting thus improving efficiency. An aftercooler is required when
Dryers require routine maintenance and drying some resins.
performance checks. • R
 educed desiccant effectiveness caused by worn-out or
A good maintenance staff that understands dryers and contaminated desiccant
has the time and support to maintain them is needed. • Nonfunctioning regeneration heater and/or process heater
The following information is provided to help give that
• Blower motor turning backwards
understanding. Dryer suppliers can also help to provide
• A
 irflow not being shifted when controls call for bed
specific information on their drying systems. Built-in dew
change; one bed stays in process continuously.
point meters available from most manufacturers default
• Uninsulated dry-air supply line
• See Table 2 for additional troubleshooting guidance. 

Table 2. Dryer troubleshooting guide

Problem Possible cause Corrective action
Desiccant worn out or saturated Dry cycle machine or replace desiccant.
Incorrect desiccant type Replace desiccant with type and size recommended by dryer manufacturer.
Regeneration heaters burned out Replace heaters.
High dew point Regeneration filter plugged Clean or replace filter.
(wet air) Regeneration blower reversed Reverse electrical connections.
Air leaks Check and repair auto loader seal and/or hoses to hopper.
Beds not changing at the proper time Reset or repair controller.
Return air too hot Add or repair aftercooler.
Dirty air filter Clean or replace filter.
Fan motor reversed Reverse electrical connections.
Low airflow Hoses reversed between inlet and outlet Connect dryer outlet to inlet at the bottom of the hopper.
No hose clamps; hose disconnected Connect and clamp hoses.
Hose smashed or cut Repair or replace hose.
Hopper too small Use larger hopper.
Short residence time Hopper not full Keep hopper full.
Tunneling Remove clumped material or install proper spreader cones.
Incorrect temperature setting Set correct temperature.

Temperature high or Temperature controller malfunction Calibrate or replace temperature controller.

low (or varying more Dryer not designed to maintain correct range Repair or replace dryer.
than ~3°C [~5°F]) Thermocouple loose or malfunction Repair or replace thermocouple.
Heater malfunction Repair or replace heater.

7
Extruder Head
Eastar amorphous copolyesters for EBM are viscous polymers The high viscosity of EBM copolyesters requires the use
and require a low-work (low-shear) screw to prevent melt of low-restriction heads to avoid excessively high head
temperature override. Best results are obtained when using a pressures and melt temperatures. Eastar copolyesters have
low-shear barrier screw designed to generate a homogeneous been successfully processed through the use of streamlined,
target melt temperature at the required output for the process. low-restriction heads, usually of the torpedo or spider type,
made of plain tool steel, stainless steel, or chrome-plated
Barrel cooling is highly recommended using either fans or
steel. Most reciprocating screw and accumulator head
circulating oil through a copper coil. If the cooling medium
machines process copolyesters well. Use standard operating
is oil, then a temperature of approximately 120°C (250°F) is
procedures to optimize actual melt temperatures.
suggested for cooling when extruding Eastman copolyesters.
Internal screw cooling is not recommended for copolyesters. Unheated die adapters are a common problem encountered
Temperature control of the extruder feed throat is in extrusion blow molding. Adequate heating capacity should
recommended. The feed throat temperature should be close be provided for the adapter and head neck areas to prevent
to the temperature of the incoming pellets from the dryer. cold spots, which can lead to an unstable parison as well as
The stock melt temperature (as measured with a handheld excessive head pressure and possible head damage.
probe as it exits the die) should be within the ranges
provided in typical processing conditions for good processing
(Table 4). Temperatures on the low side of the range provide
Die tooling selection
better melt strength, while temperatures on the high side The die tooling is selected to provide the correct parison
provide a better surface finish. diameter and wall thickness for efficient blow molding and
to give the specified container weight without capturing the
Screw design container neck. For containers formed with a presqueeze
device, adjust tooling size with blow-up ratio to optimize
Depending on the screw design, the second rear zone container wall thickness.
temperature can be raised to relieve excessive motor load.
The die tooling (bushing and mandrel) for Eastman copolyesters
In fact, depending on screw design and throughput rate, it
will be relatively large because of the very low swell factor of
is sometimes desirable to use a reverse temperature profile
this polymer. A rule of thumb is to provide a bushing with an
(rear zones hotter than front zones). Cooling on the front
inside diameter (I.D.) approximately 90% of the “E” dimension
zones can then be used to lower the melt temperature.
(root diameter) of the bottle to be molded. This applies only
Alternately, after processing has been established, the barrel
to machines that use the blow-pin method of forging the
temperature profile can be reduced to achieve a melt
bottle finish. The die opening will generally range from 0.5
temperature that optimizes processing.
to 2.5 mm (0.02 to 0.10 in.), depending on the bottle sidewall
High-compression screws designed for high-density requirement and blow-up ratio. The die bushings should be
polyethylene are not ideally suited for Eastar copolyesters, selected only after an allowance has been made for the
because they tend to generate excessive melt temperature anticipated parison die swell. Since Eastman copolyesters
which results in decreased melt strength. Screw designs with exhibit very little swell, the die size will be somewhat larger
intensive mixing can also cause increased shear heating that than some other resins, such as PVC and HDPE.
reduces the melt strength of the material. However, these
The sizes shown in Table 3 provide adequate diameter to
types of screw designs may be used if the output is low
fit the thread-finish “E” dimension (root diameter). If the
enough to reduce shear heating and the parison is short,
parison is smaller than the root diameter, it will not cut off
requiring less melt strength. Generally, the extruder setup
consistently and may slide into the mold.
suggested for extrusion blow molding of PVC and PC can be
used with Eastman copolyesters. GN046 and EB062 will exhibit slightly greater die swell at
the same melt temperature and require a slightly smaller die
Internal cooling of the first 4 to 5 flights of screws at the
tool than suggested in Table 3.
feed zone enhances pellet feeding with some materials,
especially when using low-temperature additives. Internal
cooling of the screw length, such as is common with PVC, is
not necessary for Eastar copolyesters and can lead to feeding
or surging problems. An exception is when a little air cooling
of the screw tip is used when extruding multiparisons. Contact
Eastman Technical Service for screw design information.

8
After selecting the bushing diameter, a mandrel size that Table 4. Extrusion set temperature ranges
will provide the correct parison wall thickness and specified
bottle weight must be chosen. Die and mandrel size will Eastar 6763, GN046, GN077,
and EB062 and Tritan
be determined by container wall thickness requirements.
ºC (ºF)
A thin-wall container is normally run with a narrow gap
Barrel zone 1 193–216 (380–420)
because the parison does not sag as much. A thick-wall
container will require a bigger gap to compensate for the Barrel zone 2 202–232 (385–450)
higher viscosity of the material, which is required to have less Barrel zone 3 193–232 (380–450)
parison sag and better melt strength. Parison programming
can also be used to compensate for parison sag and improve Barrel zone 4 193–232 (380–450)

container wall thickness distribution. Adapter 193–232 (380–450)

Head 193–232 (380–450)

Table 3. Approximate die bushing sizes for extrusion
blow molding of Eastar™ copolyesters 6763, GN071, and Die bushing 193–232 (380–450)
GN077, nonprogrammed Melt temperature 200–244 (390–460)

Thread “E” dim. (root diam.) Bushing I.D. Mold temperature 10–50 (50–120)
finish, mm max., mm (in.) estimate, mm (in.)
18 15.7 (0.620) 12.4 (0.490)
Table 5. Typical processing temperature ranges for
20 17.8 (0.699) 14.5 (0.570)
Eastar EB001
22 19.8 (0.778) 16.5 (0.650)
Extrusion set temperatures
24 21.7 (0.856) 18.5 (0.730) ºC (ºF)

28 25.2 (0.994) 22.6 (0.890) Barrel zone 1 260–275 (500–530)

30 26.2 (1.033) 23.6 (0.930) Barrel zone 2 270–275 (520–530)

33 29.7 (1.171) 27.9 (1.100) Barrel zone 3 270–275 (520–530)

35 32.3 (1.270) 30.5 (1.200) Barrel zone 4 265–270 (490–520)

38 35.1 (1.382) 33.0 (1.300) Adapter 247–260 (480–500)

Head 245–252 (475–485)

Typical EBM processing temperature Die bushing 245–249 (473–480)

ranges for Eastar™ copolyesters Melt temperature 275–280 (530–540)

These conditions are suggested starting points. Actual Mold temperature 10–38 (50–100)

temperatures can vary due to screw and head design,

cycle time, and container weight and geometry. Mold Extruder setup
temperatures will be dependent on container deflash
timing, die tooling, die design, weld strength, and desired For best extrusion blow molding results with Eastar copolyesters,
level of flash attachment. When possible, a multiple zone start with a clean machine. Heat-sensitive resins can leave
cooling setup is desirable to give greater control of neck degraded residue (usually burned or charred) plated on the
and base temperatures vs. sidewall temperatures. screw and die surfaces, which disperses from the equipment
and contaminates the product.
Relative to the screw design, output, and process setup,
Eastar™ copolyesters 6763, GN046, GN077, and EB062 will On extrusion start-up, the barrel temperatures can usually
generally be lower in the processing temperature range and be set within the ranges of typical extrusion conditions for
Eastar EB001 will be higher in the range. Adjust process set amorphous materials (Table 4) and crystalline materials
temperatures to achieve a homogeneous melt temperature (Table 5). The barrel and screw should be allowed to soak for
that is optimized for your process. a minimum of 1 hour after a long shutdown to prevent
damage to the machine and screw. The barrel temperatures
may then be adjusted to provide a suitable melt temperature.

9
Refer to the typical extrusion blow molding conditions given 1. W
 hen temperatures have leveled out, let the barrel and
in Table 6. The actual setup for your system will depend on screw soak for a minimum of 1 hour to prevent damage to
your equipment. Temperature profiles need to be adjusted the equipment.
to achieve an optimal melt temperature for your process. 2. W
 hen pressure is reached and flow through the head is
Precise melt temperature readings can only be obtained by full, set to the desired temperature profile.
inserting a handheld melt probe directly into the parison
3. S tart producing containers.
approximately 6 mm (0.25 in.) from the die. Infrared devices
tend to read the temperature of the outer layer of the
parison, which is closer to the metal temperature of the die
tooling than the actual melt temperature.

Table 6. Typical extrusion blow molding processing conditions

Eastar Eastar Eastar Eastar Eastar Eastar
6763 GN077 GN078 GN046 EB062 Tritan EB001
Material ºC (ºF) ºC (ºF) ºC (ºF) ºC (ºF) ºC (ºF) ºC (ºF) ºC (ºF)
Zone 1 205 (400) 195 (385) 195 (385) 200 (390) 205 (400) 215 (420) 275 (530)

Zone 2 230 (450) 215 (420) 215 (420) 215 (420) 215 (420) 235 (455) 275 (530)

Zone 3 170 (340) 215 (420) 215 (420) 225 (435) 215 (420) 230 (450) 275 (530)

Zone 4 165 (325) 205 (400) 205 (400) 225 (435) 205 (400) 225 (435) 265 (505)

Adapter 170 (340) 210 (410) 210 (410) 235 (455) 210 (410) 220 (430) 265 (505)

Head 175 (350) 210 (410) 210 (410) 220 (430) 210 (410) 220 (430) 265 (505)

Die bushing 210 (410) 210 (410) 210 (410) 220 (430) 210 (410) 220 (430) 265 (505)

Melt temperature
220 (430) 230 (450) 230 (450) 240 (460) 230 (450) 240 (470) 280 (535)
(probe)

Mold temperature 10 (50) 32/15 (90/60) 32/15 (90/60) 32/15 (90/60) 32/15 (90/60) 38 (100) 15/15 (60/60)

Tg 80 (176) 80 (176) 80 (176) 80 (176) 84 (183) 110 (230) 78 (172)

Drying temperature 65 (150) 65 (150) 65 (150) 65 (150) 65 (150) 88 (190) 150 (300)

Feed throat
65 (150) 65 (150) 65 (150) 65 (150) 65 (150) 65 (150) 93 (200)
temperature
These conditions are general guidelines. Actual conditions may vary based on barrel and screw size, screw design, part design and weight, cycle time, and material being processed.

10
Typical preparation, start-up, line-out, can process on even faster cycles. The in-mold cooling
and shutdown procedures for extruding typically requires 3–6 seconds for most average-weight
bottles. Make adjustments in mold centering, die, blow
Eastar amorphous copolyesters
pins, and cutters as required. The blow-pin cutting
Preparation washers must be sharp and accurately set for good
trimming. Continue to adjust the extruder zone heaters
1. S elect a low-shear screw and low-restriction (free-
and barrel cooling circulator to obtain a melt temperature
flowing) die head assembly. This setup prevents excessive
in the range recommended in Tables 4 and 5. The melt
melt temperature from screw-shear heating and head-
temperature may tend to increase, and the barrel settings
back pressure.
may require readjustment during the first hour or so of
2. S elect die tooling large enough to accommodate the operation. Adjust the die bushings temperature control to
bottle weight and thread-finish diameter required. achieve the best surface finish, gloss, and clarity.
3. Start with a clean screw and die head assembly. 5. A
 djust the extruder speed to obtain proper parison length,
4. P redry the resin for 6 hours in a low-dew-point dryer and adjust the parison program as required.
system at 65°C (150°F). 6. C
 heck bottle weight, wall thickness uniformity, and thread
5. S et the extruder zones according to the recommendations finish quality. If necessary, change the tooling to get the
in Table 4. To ensure the adapter head and extrusion required parison diameter and bottle weight.
system are adequately heated, allow at least 1 hour
heating (soak) after temperatures are at the set point. Shutdown procedure
Extruder barrel feed throat control is recommended to
For a short shutdown time (2 hours or less), it is not necessary
prevent pellet bridging and enhance pellet feeding.
to turn the heaters off, but it is desirable to do so for longer
6. Set the mold coolant temperature controls. shutdown periods. The best procedure is to empty screw by
7. Sharpen the parison cutoff knife. shutting off pellet feed to extruder and allowing the screw to
8. C
 heck sharpness of blow-pin flash cut washer (cutter ring) empty of unmelted pellets.
and the mold striker plates. Turn cooling on blow pin. Do not use PVC purging material because PVC will char,
causing black flakes to appear in the copolyester melt during
Start-up and line out subsequent extrusion start-up.
1. S tart the extruder motor while the extruder is empty. 1. S hut off pellet flow by shutting off the hopper feed-throat
Open the hopper and allow material to enter the feed slide valve.
throat. Observe the motor-load indicator for satisfactory
amperage load. 2. S top the mold cycling.

2. V
 ary the temperature of the extruder zones as necessary 3. A
 llow the extruder to run empty, stop extruder, and then
to obtain a melt temperature in the range indicated in turn heat off.
Table 4. Check the melt temperature with a handheld
4. F or a short downtime (approximately 2 hours or less), the
pyrometer placed directly into the parison melt stream
barrel and die heat may be left on and at the operating
about 6 mm (1/4 in.) from the die exit. Spray the probe
temperature setting. Restart by starting screw rotation,
with silicon or mold release to reduce the amount of
then open hopper gate to start pellet feeding.
material that sticks to the metal probe.
3. A
 djust the die(s) so that the parison extrudes uniformly 5. F or an extended shutdown, the heaters may be turned off.
straight down. Readjustment may be required as the
temperature stabilizes. On multihead units, adjust the Restarting procedure
manifold heat for balance of parison flow for all die heads. For restarting after a heat-off shutdown with Eastar
4. B
 egin cycling the mold press. Cycle time settings are copolyesters in the die head and adapter, refer to the “Start-up
normally the same as for other resins (typically 8–12 and line out” procedure. It is important to monitor motor-
seconds for a 2-station machine), depending on container load amperage and head pressure gauge for an alarm
size and weight. Small containers (180 mL [6 fl oz] or less) condition during restarts.

11
Typical preparation, start-up, line-out, Shutdown overnight procedure
and shutdown procedures for Eastar 1. S top screw with barrel full of EB001.
EB001 crystalline copolyester 2. S et heat to 280ºC (540°F), but do not turn heat on until 2
hours before running.
Preparation
3. T
 o save time on start-up, the temperatures can be banked
1. S elect an optimized screw and low-restriction (free- overnight at a temperature below the melting point of
flowing) die head assembly. This setup prevents excessive EB001 (see Tg on Table 6).
melt temperature from screw-shear heating and head-
back pressure.
2. S elect die tooling large enough to accommodate the
Regrind
bottle weight and thread-finish diameter required. A significant percentage of the total parison weight becomes
3. Start with a clean screw and die head assembly. trim scrap in the extrusion blow molding process; economics
4. P redry the resin for 6 hours in a low-dew-point dryer therefore require that as much of this scrap as possible be
system at 150°C (300°F). reused. The excellent thermal stability of Eastman
5. S et the extruder zones according to the recommendations copolyesters permits the complete reuse of all clean, dry
in Table 4. To ensure the adapter head and extrusion regrind. However, care must be taken to prevent
system are adequately heated, allow at least 1 hour contamination of the regrind by other plastics, dust, dirt,
heating (soak) after temperatures are at the set point. paper, labels, caps, purgings, etc., in the scrap handling
Extruder barrel feed throat control is recommended to equipment; otherwise, clarity and toughness of blow molded
prevent pellet bridging and enhance pellet feeding. items could be reduced. Degraded purged extrudate should
6. Set the mold coolant temperature controls. be discarded and not reused. Typical grinder screens have
7. Sharpen the parison cutoff blade and turn on hot knife. openings of 8 mm (5/16 in.) and 10 mm (3⁄8 in.). Grinder blades
should be sharp to reduce fines. Dry all good regrind at the
8. C
 heck sharpness of blow-pin flash cut washer (cutter ring)
conditions recommended for the base resin.
and the mold striker plates. Turn cooling on blow pin.
Note: EB001 regrind is amorphous and will recrystallize
Start-up and line out during drying.
1. Set heat to 280ºC (540°F) for 1.5 to 2 hours.
2. D
 ouble check that temperatures are at the correct set Parison cutting
point (Table 5) before turning on hydraulics.
3. Open die gap to 100%. A cutoff knife is used to cut the hot parison so that the
4. Clean die and mandrel with die soap and copper gauze. mold can move it away from the die to the blow station.
5. S tart screw at 10 rpm and ramp up 5 rpm until reaching Either a cold-knife or hot-knife method has been found to
a maximum of 20 rpm. provide reliable results with amorphous Eastar copolyesters.
A hot knife is required for EB001. The blade should be well
6. Purge for 20 minutes at 20 rpm.
sharpened and fairly close to the mold. A clearance of
7. Input temperature profile for EB001 (Table 5) after
approximately 13–19 mm (0.50–0.75 in.) is desirable.
20 minute purge.
A similar clearance between the blade and the extrusion
8. A
 llow barrel and head temperatures to stabilize before die is also preferred. Sufficient activation pressure should
attempting to make bottles be used to provide a rapid knife cut. For inflated parisons,
a prepinch setup with a standard cold knife or a linear-cut
Shutdown and purge procedure when process is
hot knife can be used for amorphous Eastar copolyesters.
down for 10 minutes or longer
A prepinch, linear-cut hot knife is required for Tritan TX1800
1. Increase temperatures to 280ºC (540°F) and let soak and EB001 handleware containers.
for 20 minutes.
The parison inflation air must be precisely adjusted to
2. After 20 minutes, open die gap to 100%.
provide the correct amount of parison expansion just prior
3. S tart screw at 10 rpm and ramp up 5 rpm until reaching
to the knife cut. The parison must also be sized (with die
a maximum of 20 rpm.
tooling) to fit the mold thread finish properly to ensure a
4. P urge for 20 minutes or until the parison is clear good cut with the top of parison remaining open for the blow
of unmelted pellets. pin insertion. If the parison is too small and is not properly
5. Input temperature profile for EB001 after purging. held by the mold at the thread area, it will not be possible to
6. A
 llow barrel and head temperatures to stabilize before get a good parison cut and the top of the parison will close
collecting bottles. to one side. Excessively high melt temperatures can also
contribute to this problem.
12
Parison programming Mold cooling channels
Most molds should be segmented for three-zone cooling of
Programmable dies are beneficial to controlling the material
the base, body, and finish-handle areas. Segmented mold
wall thickness distribution when blow molding Eastar
cooling allows optimized deflashing temperature of base,
copolyesters. A parison programmer is sometimes used
handle, and neck. Optimized deflashing temperature can
with containers that have a widely varying cross-sectional
result in improved bottle transfer on systems using tail
diameter so that a uniform bottle wall thickness can be
grippers to move the containers from the mold to the deflash
achieved. The tooling should be selected so that the mandrel
stations. Optimized cooling can also lead to better container
does not extend more than 4 mm (0.16 in.) beyond the
performance when subjected to drop impact testing..
bushing during opening of the programmed movement. 

Pinch land design

Container and mold design for Typical pinch lands are 0.006–0.012 in. wide, with amorphous
Eastar™ copolyesters being at the high end of the range and EB001 at the lower
Shrinkage rate end of the range, tapering at 45° into the pinch pocket. A
stronger pinch weld can be achieved by tapering from the
The shrinkage rate for amorphous copolyesters is in the pinch land at 30° for a short distance into a 45° angle leading
range of 0.003–0.006 in./in. (0.0762–0.1524 mm/mm). into the pinch pocket. Alternately, a short dam of 0.100 in.
Most mold makers use a shrinkage rate of around 0.004 width can be introduced after the 30° angle before leading
in./in. (0.1016 mm/mm). The shrinkage rate for Tritan is 45° into the pinch pocket. The pinch lands should be “proud,”
0.005–0.007 in./in. (0.127–0.1778 mm/mm). The shrinkage i.e., extend above the mold face by 0.0005–0.0015 in. A light
rate for EB001 is the same as EB062, 0.003–0.006 in./in. hand honing of the hardened pinch lands is sometimes
(0.0762–0.1524 mm/mm). helpful to remove sharp, rough edges from newly machined
mold faces.
Container design
The container should be designed with long, gentle radii to Mold surface
help disperse drop impact forces. Draft angles and container
A mold with a standard polish or glossy surface finish works
design features should allow easy release of the container
well with most mold cavity configurations. A smooth matte
from the mold. The base footprint should be wide with a long,
finish, such as that produced by vapor honing or jet blasting
gentle radii leading into the base push-up. The best impact
with a mixture of water and fine glass beads (such as No. 13
properties are achieved when the parison pinch length is
beads), has been used successfully. The smooth matte finish
contained within the base push-up. The base footprint should
is preferred for cylindrical cavity configurations and is
be gently recessed at the thick parison pinch termination
suggested for any other configurations that tend to have
points to minimize impact stress at the thick-to-thin
venting problems. Venting problems usually appear as wavy
transition of this area. This base pinch tunnel should be
or splotchy areas on the outside surface of the blow molded
shallow with a generous width and then taper gently into
item. These wavy or splotched areas are caused by entrapped
the footprint. Locate any base indexing notches or engravings
air between the parison and the mold surfaces. The microscopic
away from the pinch area. Keep engravings shallow
matte finish on the mold prevents the formation of air pockets
(approximately 0.008 in. deep) with generous, soft radii.
by reducing the degree of surface contact and allowing the
Any sidewall features should have long, generous radii to
air to escape through vents. Cavity vents can be added to the
help disperse impact and flexure forces. Standard venting
mold to vent problem areas. Copolyesters pick up the mold
guidelines apply
texture surface easily, so adjust mold surface accordingly.
Mold materials
Predelivery evaluation
The body of the mold is typically mold grade aluminum or
Prior to delivery of the mold, it should be leak and flow
BeCu HH. For improved durability of aluminum mold pinch
(Reynolds number appropriate for cooling fluid turbulent
lands, use pinch land inserts of BeCu HH or hardened tool
flow) tested. A carbon paper compression imprint of the
steel (S7, up to 55–60 Rockwell C).
mold contact areas should be presented showing parallel
compression of parting line and pinch lands. Unit cavity
evaluation of the mold is prudent if working with a new
container design.

13
Melt fracture Melt fracture (surface roughness of the container) can occur
at low melt temperatures, high outputs, and with restricted
Melt fracture is evidenced by a rough surface finish on the
or rough die tooling. Methods that can reduce melt fracture
plastic as it exits the extrusion die. It usually appears as very
include die cleaning and polishing the die tool to a mirror
tiny wavy lines around the circumference of the parison. Melt
finish, coating the tooling with a low coefficient of friction
fracture can occur on the inside or outside surfaces of the
material, increasing die gap opening, or opening die angles.
parison. Most internal surface problems are not noticeable
when the molded container is filled with a liquid product.
Deflashing
The visible effect of surface roughness is reduced during the
The minimum molding machine clamp tonnage required for
blow molding process by the stretching and elongating of the
deflashing copolyesters is 0.28 ton (U.S.) per inch of linear
parison and by the relaxing of surface disturbances. The first
pinch (about 2 × the requirement for PVC and HDPE).
step in reducing melt fracture is to raise only the die bushing
temperature. If this heater cannot maintain sufficiently high If the mold is handleware, go extra deep in the handle pinch
bushing temperatures, a heater band of larger electrical pocket to allow the flash to remain warm. The flash should
wattage should be installed. Refer to Tables 4 and 5 for detach easily to prevent microfissures that can propagate
recommended die bushing temperature range. After start-up to a crack upon impact. Deflashing should normally be
of the extrusion process, the die bushing temperature can be completed within 30 seconds of molding. The best container
adjusted to obtain the best container surface finish. impact results can be achieved by deflashing when the
polymer at the base pinched flash to container interface has
The next step is to raise the melt temperature slightly, which
a leathery flex feel vs. being rigid or rubbery. Generally, this
reduces the melt viscosity of the polymer and, consequently,
leathery state is achieved within 30 seconds of molding and
reduces shear stress of the melt in the die; this, in turn, reduces
is around 80° to 95°C (180° to 200°F) when measured with
the degree of melt fracture.
an IR temperature measuring instrument.

Table 7. Eastar™ copolyesters extrusion blow molding troubleshooting guide

Problem Possible cause Possible remedy

• Decrease barrel heat.
• Employ a low-work barrier screw.
Melt temperature too high • Use a reverse temperature profile.
Poor melt strength • Cool front zones.
• Avoid restrictive adapter and head. PVC/copolyester dies generally work best.

Inadequate drying • Troubleshoot drying system.

• Use proper screw design.
• Do not use internally cooled screws; cool screw only in the first 4 to 5 flights of
the feed zone.
• Ensure regrind is not blocking/bridging hopper throat and is at a consistent size and
Inconsistent pellet feeding blend percent.
• Increase back pressure by cooling adapter or head cooling.
• Reaffirm proper drying. Copolyesters dried at temperatures greater than 70°C (160°F)
Surging may bridge feed throat.

• Use lower percentage of regrind. May be experiencing poor material pickup by screw
and/or nonuniform packing on the screw.
Improper temperature • Ensure die bushing heat is uniformly controlled.
• Ensure that all heaters or controllers are at set point.

Programming • Ensure parison programmer is operating properly.

• Ensure proper venting of mold.
• Jet blast mold surface (No. 13 bead or 220 grit).
Air entrapment
Splotched surface • Vapor hone mold surface.
finish • If mold is highly polished, radial wipe to vents with 600-grit sandpaper.
• Increase mold temperature to eliminate condensation.
Moisture condensation
• Install a controlled atmosphere enclosure with a low dew point.

(Continued on next page)

14
Table 7. Eastar™ copolyesters extrusion blow molding troubleshooting guide (continued)

Problem Possible cause Possible remedy

• Increase temperature of die bushing surface.
• Increase melt temperature.
Melt fracture/ • Increase die opening.
Parison surface stress
surface haze • Reduce extrusion rate.
• Polish die tooling surface.
• Coat polished die tooling with low coefficient of friction coating.
• Use generous radii in bottle design.
• Locate index mark away from pinch-off area.
• Maximize impact surface area.
Poor container design
• Use a base push-up design.
• Optimize minimum wall thickness between 0.38 and 0.64 mm (0.015 and 0.025 in.) for
most containers.
Poor drop impact • Ensure pinch weld integrity.
resistance
• Perform pinch area maintenance (flash should detach easily).
Mold • Ensure pinch-off termination does not extend into impact area of base.
• Increase mold temperature.
• Trim flash immediately after molding while pinch weld is still hot.
• Minimize molecular weight degradation by drying properly.
Material issues
• Increase melt temperature.
• Use knife with sharp edges.
Poor knife setup • Provide rapid cut.
Poor parison cutoff
• Increase hot-knife temperature.
Inadequate melt strength • Reduce melt temperature
Inadequate drying • Troubleshoot drying process
Bubbles
Air entrapment • Use proper screw design and optimize barrel temperature profile.
• Increase die size.
• Increase support air volume.
Parison slipping
• Adjust knife cut timing.
in mold
• Apply vacuum to finish area of mold.
• Use side pinch or flashed neck.
• Increase barrel temperature for start-up and then readjust to optimize processing
Screw load too high Material not to proper melting conditions.
upon restart temperature
• Allow longer soak time.
• Replace, realign, or resharpen cutting washers.
Rough surface finish Dull cutters or mold striker • Use washers with raised cutting surface.
trim plates • Increase blow-pin calibration pressure.
• Trim hotter.
• Use barrier screw with low-work mixer.

Uneven parison • Cool screw tip slightly with small amount of air.
Nonhomogeneous melt
control on multiple temperature
• Use better temperature control at adapter and splitter.
heads • Use individual head temperature controllers.
• Use proportional temperature controllers on each die bushing.
Degraded material or • Always clean and polish all die surfaces at each start-up and when going from
Die lines contaminates PVC or PC to Eastar™ copolyesters.
Trim sticks to bottle Hot flash • Use trim separation at mold ejection.
• Adjust blow-pin cutter and mold striker to cut closer.
• Maintain pinch lands to original specifications.
Container fractures Deflasher
• Trim flash while hot immediately after molding.
• Contour the deflash impactor to the shape of the container.

Conversions of metric/U.S. customary values may have been rounded and therefore may not be exact conversions.

15
 Although the information and recommendations set forth herein are presented in good faith, Eastman Chemical
Company and its subsidiaries make no representations or warranties as to the completeness or accuracy thereof.
You must make your own determination of its suitability and completeness for your own use, for the protection
of the environment, and for the health and safety of your employees and purchasers of your products. Nothing
contained herein is to be construed as a recommendation to use any product, process, equipment, or formulation
in conflict with any patent, and we make no representations or warranties, express or implied, that the use thereof
will not infringe any patent. NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, OF
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Safety Data Sheets providing safety precautions that should be observed when handling and storing our products
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SP-MBS-1605 7/16