Technology and Application of PET Training

Blowing Nomenclature
Pre Blow - First Blowing Pressure PET requires a slow inflation rate to achieve designed orientation and stretch levels High Blow - Second Blowing Pressure High pressure is required to form the corners and quench material in base Flow controls change the rate of blowing All stations have flow controls for low air, some machines have flow controls on the high air system

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Technology and Application of PET Training

Preform Heating
Package Design

Material Properties

Process Requirements

Performance Requirements

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Preform Heating
Objectives: Understand the Nature of the source of IR Energy and the absorption of IR by PET preforms Learn why preforms tend to be hotter on the outside than on the inside after heating with IR Understand some of the limitations of the IR heating process

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Electromagnetic Radiation

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Technology and Application of PET Training

IR Absorption Characteristic of PET

1.20

1.00

0.80

0.60

0.40

0.20

0.00 0.00

1.00

2.00

3.00

4.00

5.00

6.00

Wavelength (m)

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Technology and Application of PET Training

IR Transmission Characteristic of PET

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Technology and Application of PET Training

Output of Quartz Heater Elements

Spectral Radiation Distribution
Monochromatic Radiating Power (J/(m2*s)
1.2E+12 1.0E+12 8.0E+11
2200 K

2400 K

6.0E+11 4.0E+11 2.0E+11 0.0E+00 0 1 2 3 4 Wavelength (m) 5 6 7 8

2000 K 1800 K 1600 K 1400 K

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Technology and Application of PET Training

Sidel IR Heaters

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Technology and Application of PET Training

Absorption of IR by PET Preform

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Technology and Application of PET Training

PET Resins Vary In Absorption Properties

IR Absorption of PET
0.10 0.09 0.08 0.07 0.06 Slow Heating Resin Medium Heating Resin Fast Heating Resin

Absorption Properties Of PET

0.60 0.50 0.40 0.30 0.20 0.10 0.00 0.000 0.500 1.000 Wavelength, Microns 1.500 2.000 Slow Heating Resin Medium Heating Resin Fast Heating Resin

0.05 0.04 0.03 0.02 0.01 0.00 1.000 1.050 1.100 1.150 1.200 1.250 1.300

Wavelength (M)

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This Affects How Quickly Preforms Heat Up

Comparison of Heatup Rates
115 Temperature at Blow, Deg. C 110 105 100 Fast heating 95 90 1 2 3 4 5 6 7 8 9 10 Inside to Outside Wall Position Medium Heating Slow Heating

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Technology and Application of PET Training

Oven
The oven is used to heat preforms: The function of the infrared oven is to bring the preforms to a temperature of between 90 and 120 degrees C before they are stretched and blown in the blow wheel. The oven boxes around the edge of the oven wheel are needed to reheat the preforms. Each oven box is personalized for the preform.
The oven can have different number of lamps to fit the need of the preform. The oven box can be removed easily
It is connected to the power supply by a multi-pin plug.

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Technology and Application of PET Training

Schematic of Heating System

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Technology and Application of PET Training

Oven

Courtesy of SIDEL

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Technology and Application of PET Training

Oven
The number of the lamps depends on the type of preform to be reheated and the bottle to be blown On each module there are two fans
One which blows air towards the ends of the lamps A second fan forces air flow across for the preform to keep the outside of the preform from overheating.

Neck shields with circulating water protect the necks by preventing the infrared radiation from heating the finish
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Technology and Application of PET Training

More SIDEL Heating Hardware

15 mm Spacer Lamp Out

Spacer Lamp In

Clean Reflective Plate

15 mm Lamp Holder

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Technology and Application of PET Training

SIDEL Heating Hardware

Dirty Heater Side Reflector

Clean Cooling Side Reflector

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Oven Adjustments

Courtesy of SIDEL

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Air Circulation Through the Oven

Air is blown on the finish after the preform leaves the first row of ovens and before entering the second row of ovens Air is blown across the preform to cool the surface of the preform

Courtesy of SIDEL

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Example for A Wavelength Where 1 mm of PET absorbs 10%

100%

1mm 1mm 1mm 1mm

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Example for A Wavelength Where 1 mm of PET absorbs 10%

100% 90%

Layer Absorbs

10% 1mm 1mm 1mm 1mm

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Example for A Wavelength Where 1 mm of PET absorbs 10%

100% 81% 90%

Layer Absorbs

10%

9%

1mm 1mm 1mm 1mm

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Example for A Wavelength Where 1 mm of PET absorbs 10%

100% 81% 73% 90%

Layer Absorbs

10%

9%

8%

1mm 1mm 1mm 1mm Preform is Hotter Towards Outside

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Technology and Application of PET Training

25% 450 Watts 90 Volts 1490 Degrees C

IR Heating in PET with 2000 Watt Lamps

65% 1160 Watts 165 Volts 1885 Degrees C 100% 1800 Watts 220 Volts 2150 Degrees C

The length of the wave emitted by the infrared lamps is only optimal when the lamps have nearly reached their rated power
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Explanation of Interaction of Heaters

Intensity is greater in the center of the array. Each heater affects a large area.

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Special Hardware to Control Heat Zones Precisely

Zone Shield

Quartz Focusing Lens and Bracket

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Material Distribution Example, Zone 3 Power to 55%

0..332mm / 0.0130

0.348mm / 0.0137

0.287mm / 0.0113

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Material Distribution, Increasing Zone 3 Power to 99%

0.364mm / 0.0143

0.306mm / 0.0125

0.280mm / 0.0110

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Technology and Application of PET Training

Free Blowing at Different Temperatures

2 Liter 950

2 Liter 1100

2 Liter 1150

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Oven Lamp Control, Krones

Individual Lamps can be turned on and off. Lamp power can be adjusted in conditioning ovens.
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Power Output Curve to Regulated Ovens

The oven will switch to the standby setting when all of the preforms have exited the oven The power will change to 100% when preform loading has been pressed The % of power will switch to the production startup setting after the oven has reached the loading set point and preforms will start to enter the machine The percent of power will change to adjust the heat to meet the preform set point (IN AUTO)
Courtesy of SIDEL

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Technology and Application of PET Training

Oven Control

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Important Considerations in Reheating Process

Material is heated from the outside to inside Cooling air is a process aid to prevent overheating of the outside Absorption characteristics of PET resins vary widely Heat zones in a quartz oven are highly coupled Adding and subtracting heat usually is a better process change to move material Running heat zones above 50% is generally a good practice Peak output wavelength is more favorable to penetrate PET Old quartz tubes tend to emit longer wavelength energy Ovens should be relamped on a bi-annual basis, more frequently for demanding applications such as preforms with high blow up ratios

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Preform Heating Summary

The purpose of the heat profile controls is to impart an axial temperature distribution on the preform which controls material distribution in containers The nature of this temperature distribution is very complex PET Preforms tend to be hotter on the outside than on the inside after heating with IR Single stage process tends to run a hotter preform than the two stage process

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Stretch Rod Movement

P0 (P zero) Refers to angle in degrees at the point where the stretch rod engages the preform

P10 (P ten) Refers to the angle in degrees at the point where the stretch rod fully stretches the preform
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