Blow Moulding Process

Alok Pathak
24/RAC/03
M.Tech. (R)
 Introduction
 Blow moulding is a process for converting thermoplastics into hollow
objects for industrial applications and consumer containers for food,
beverage, pharmaceutical, and cosmetics products.
 Blow moulding is quite useful in the production of pharmaceutical
packaging, such as bottles for ophthalmic solutions. A unique
technology called blow-fill-seal allows the formation of the package,
and the filling of the container, all in the same equipment – and
under aseptic conditions.
 Blow moulding is a vital manufacturing process due to its efficiency and
versatility in producing hollow plastic products.
 Blow moulding supports a wide range of applications across various
industries, including packaging, automotive, and consumer goods,
making it an essential technique in modern manufacturing.
 Origin of Blow moulding
 The origins of blow molding can be traced back to the early 20th
century, with its roots in glassblowing.
 Glassblowers used air pressure to expand a molten glass into a
mold, creating hollow objects. In the 1930s, similar principles were
applied to plastic processing, particularly as plastic materials
became more commercially available.
 In 1939, the first blow-molded plastic bottle was produced using a
method similar to glassblowing.
 This laid the foundation for modern blow molding, but it wasn't
until the 1950s that the process began to evolve into a commercial
technique for producing large quantities of plastic products.
 Blow Moulding Process
 1. Material Preparation
 Before the forming process begins, plastic material must be prepared for
molding. This involves the following steps:
• Polymer Resin: The raw plastic material, typically in the form of pellets or
powder, is fed into the blow molding machine.
• Heating: The plastic is heated to a molten or semi-molten state (depending
on the material and process) so it can be molded. The heating process is
done in the machine’s barrel, where the resin is melted and mixed uniformly
to ensure consistent processing.
• Colorants/Additives: Sometimes, colorants, UV inhibitors, or other
additives are mixed with the base polymer to give the product its desired
color, strength, or properties.
 2. Forming the Parison
 The parison is the preliminary shape or "preform" of the final
product. The parison is essential because it forms the base that will
be expanded into the desired shape through air pressure.
• Extrusion Blow Molding: In this process, a continuous tube
(parison) of molten plastic is extruded through a die. The parison is
cut to the required length, and the two halves of the mold are closed
around it.
• Injection Blow Molding: Here, the parison is created by injecting
molten plastic into a mold to form a preform. The preform is then
transferred to the blow mold.
• Stretch Blow Molding: A preform is created by injection molding,
and this preform will be reheated and stretched before blowing.
 3. Mold Closure
 Once the parison is formed and positioned, the blow molding
machine closes the mold halves around the parison:
• The mold is typically made of two halves that clamp together,
securing the parison between them.
• The mold cavity shape determines the final product's external
shape, while the interior of the mold creates the hollow cavity
of the object.
 4. Blowing
 This is the critical stage in which the parison takes on the final shape:
• Air Injection: Once the mold is closed around the parison, high-pressure
air is injected into the parison (through a nozzle or blow pin). This forces
the parison to expand and fill the cavity of the mold, creating the desired
hollow shape.
• Stretching (for Stretch Blow Molding): In some cases, especially in
stretch blow molding, the parison is first mechanically stretched (either
vertically or horizontally) to align the polymer chains, which improves the
strength and clarity of the final product. This step is typically used for
products like PET bottles.
 5. Cooling
 Once the mold is fully filled, the plastic is allowed to cool and solidify.
Cooling is crucial to ensure that the final product retains its shape and size.
The mold may have cooling channels built into it, through which water or air
flows to speed up the cooling process.
• The cooling time depends on factors like the thickness of the walls and the
material used.
 6. Mold Opening and Ejection
 After the plastic has cooled and solidified, the mold is opened:
• Ejection: In most blow molding processes, the mold halves are opened, and
the formed product is ejected. This is typically done using mechanical ejectors
or air blast mechanisms. In some machines, robots or other automated systems
are used to remove the products.
• Trimming (if needed): Often, there may be excess material (flash) around the
neck or edges of the molded item. This flash is typically trimmed or cut away
during this stage.
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 Types of Blow Moulding

Extrusion Blow Moulding

Injection Blow Moulding

Stretch Blow Moulding

 Extrusion Blow Moulding

 Extrusion blow moulding involves the extrusion of a parison

with a predetermined length which is held by a split die on its
ends.
 The parison is sealed in one end while the other end is fitted to
an air supply.
 Compressed air is introduced which inflates the parison. The
dies are typically cold which cools the inflated molten plastic
as it meets the die surface
 When the dimensions of the product are stable, the mold is
opened to eject the product.
 Injection Blow Moulding
 This process combines injection molding in forming the preform
with blow molding
 The injection blow molding process starts by melting and
homogenizing the plastic.
 This is done in a plastifier and screw extruder which is typically a
reciprocating screw. This operates with similar principles to that of
the intermittent extrusion process.
 Its main difference is the use of a preform mold with a metal rod
enclosed in the center
 The typical mounting of these metal rods is a rotating table with
three sections, each corresponds to a phase of the blow molding
cycle.
 Stretch Blow Moulding
 Stretch blow molding, also known as injection stretch blow
molding, is basically a modification of the injection blow molding
process.
 This process also includes the three main phases with an
additional step in the blow molding phase
 In stretch blow molding, the preform is created by injecting the
plastic melt into a die with a metal road at the center.
 The developed preform is then transferred to the product mold in
preparation for the blow molding phase
 The main objective of stretch blow molding is to create a product with
a biaxially oriented plastic. Biaxial orientation is the process in which
the plastic is stretched in two directions.
 In the longitudinal direction, the plastic is stretched by the stretch rod
while in the lateral direction, the plastic is stretched by inflation.
 Parison control
 Parison control is a critical aspect of the blow molding process,
particularly in ensuring the quality and consistency of the final product.
 The parison is a hollow tube of molten plastic that serves as the starting
point for shaping the final item.
 Effective control over the parison's characteristics directly impacts the
efficiency of the blow molding process and the quality of the finished
product.
 The parison is created by extruding or injecting molten plastic into a
specific shape.
 Its dimensions, thickness, and uniformity play a crucial role in the blow
molding process, affecting the strength, appearance, and performance of
the final product.
 Methods of parison control
 Extruder Adjustment: The settings of the extruder can be adjusted to control the
flow rate and temperature of the molten plastic, which directly affects the parison's
characteristics.
 Die Design: The design of the die used to form the parison can be engineered to
achieve specific shapes and thickness distributions. Adjustable die gaps and profiles
can help in achieving desired results.
 Blow Pressure Regulation: The pressure at which air is introduced into the parison
during the blowing phase is critical. Proper regulation ensures that the parison
expands evenly and fills the mould completely.
 Parison Length Control: Controlling the length of the parison is important,
especially in processes like injection blow molding. The length must be sufficient
to fill the mould without excessive excess material.
 Application of Blow Moulding
Here are some of the primary applications of blow molding machines across different
sectors:
 1. Packaging Industry :Blow molding is predominantly used in the packaging sector,
particularly for making containers like bottles and jars.
 2. Automotive Industry :Blow molding is used to manufacture both exterior and
interior automotive parts, offering the ability to create large, lightweight, and durable
components.
 3. Consumer Goods :Blow molding is used to create a variety of consumer products.
The flexibility of the process allows for the production of lightweight, durable, and
sometimes decorative items.
 4. Industrial and Commercial Applications :Blow molding is also widely used in the
production of larger, industrial-grade products where strength and durability are
required.
 5. Medical and Pharmaceutical Products :In the medical field, blow molding
machines are used to manufacture sterile, precision products that require high levels of
cleanliness and exact specifications.
 ADVANTAGES OF BLOW MOULDING
Blow molding offers several significant advantages, making it a preferred manufacturing process
for producing a wide variety of hollow plastic products. Here are the main advantages of blow
molding:

• Cost-effective for high-volume production.

• Design flexibility for producing complex shapes and varied wall thicknesses.
• Lightweight products, ideal for packaging and transportation.
• Material efficiency, with minimal waste and the ability to use recycled materials.
• High production speed and rapid cycle times, leading to increased throughput.
• Strength and durability, with good impact and pressure resistance.
• Multi-layer capabilities for products with enhanced barrier properties and additional
functionalities.
• Reduced post-processing and minimal need for secondary operations.
• Customization flexibility for producing various sizes, shapes, and specialized features.
 DISADVANTAGE OF BLOW MOULDING
1. Limited to hollow parts – Not suitable for solid products.
2. High initial tooling costs – Expensive molds, particularly for large or complex shapes.
3. Design limitations – Challenges with extreme thin walls, intricate features, and complex
geometries.
4. Complex mold design – Requires careful consideration of mold features and maintenance.
5. Material limitations – Generally restricted to thermoplastics; some materials are not
compatible.
6. Surface finish quality – Potential for imperfect surface finish, flash marks, and uneven
textures.
7. Limited flexibility for low-volume production – High upfront costs make it unsuitable for
small production runs.
8. Quality control issues – Variability in wall thickness and defects like thin spots and voids.
9. Environmental concerns – Waste generated from trimming flash and energy consumption.
10. Size and weight limitations – Not suitable for very small or highly detailed parts.
11. Product cooling time – Cooling for thicker parts can increase cycle time.
 REFERENCE
•"Blow Molding Handbook" by Donald V. Rosato, Marlene G.
Rosato, and Phyllis A. Rosato
A comprehensive guide that covers blow molding processes in detail,
including technical aspects, material considerations, and applications
across industries.
•"Plastic Part Design for Injection Molding" by Douglas M. Bryce
While focused on injection molding, this book also touches on blow
molding techniques and design considerations for plastic parts.
•"Polymeric Materials Encyclopedia" by J.C. Salamone (Editor)
This encyclopedia includes sections on blow molding and
various plastic forming processes, offering details on material
properties and processing methods.
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