guys you can take this ppt and read for polymer chemistry in making of molding in industry and to make bottles and also used for research purpose

1. Plastics
Blow Molding

2. Blow Molding
• Blow molding (also blow forming) is a manufacturing process by which
hollow plastic parts are formed.
• In general, there are three main types of blow molding:
– Extrusion blow molding
– Injection blow molding
– Stretch blow molding
Swimming pool ladder

3. Blow Molding
• The blow molding process begins with melting down the plastic and
forming it into a parison or preform.
• The parison is a tube-like piece of plastic with a hole in one end in which
compressed air can pass through.

4. Blow Molding
• The parison is then clamped into a mold and air is pumped into it.
• The air pressure then pushes the plastic out to match the mold.
• Once the plastic has cooled and hardened the mold opens up and the part is
ejected.

6. Blow Molding

7. Blow Molding

8. Blow Molding

9. Blow Molding

12. Blow Molding
Extrusion blow molding:
• In extrusion blow molding (EBM), plastic is melted and extruded into a
hollow tube (a parison).
• This parison is then captured by closing it into a cooled metal mold.
• Air is then blown into the parison, inflating it into the shape of the hollow
bottle, container or part.
• After the plastic has cooled sufficiently, the mold is opened and the part is
ejected.

13. Blow Molding

14. Blow Molding
Extrusion blow molding:
• Continuous and Intermittent are two variations of Extrusion Blow Molding.
• In Continuous Extrusion Blow Molding the parison is extruded
continuously and the individual parts are cut off by a suitable knife.
Toy
Fuel tank

15. Blow Molding
Extrusion blow molding:
• In Intermittent blow molding there are two processes:
– Straight intermittent is similar to injection molding whereby the screw
turns, then stops and pushes the melt out.
– With the accumulator method, an accumulator gathers melted plastic
and when the previous mold has cooled and enough plastic has
accumulated, a rod pushes the melted plastic and forms the parison. In
this case the screw may turn continuously or intermittently.
BucketCane

17. Blow Molding
Injection blow molding:
• The process of injection blow molding (IBM) is used for the production of
hollow glass and plastic objects in large quantities.
• In the IBM process, the polymer is injection molded onto a core pin; then
the core pin is rotated to a blow molding station to be inflated and cooled.
Traffic cones
Shampoo bottles Support bases

18. Blow Molding
Injection blow molding:
• This is the least-used of the three blow molding processes, and is typically
used to make small medical and single serve bottles.
• The process is divided into three steps:
– Injection
– Blowing
– Ejection
Filters
Washing machine
body
Fence feet

19. Blow Molding
• The injection blow molding machine is based on an extruder barrel and
screw assembly which melts the polymer.
• The molten polymer is fed into a manifold where it is injected through
nozzles into a hollow, heated preform mold.
• The preform mold forms the external shape and is clamped around a
mandrel (the core rod) which forms the internal shape of the preform.
Vacuum tank
Bird house

20. Blow Molding
• The preform consists of a fully formed bottle/jar neck with a thick tube of
polymer attached, which will form the body.
• The preform mold opens and the core rod is rotated and clamped into the
hollow, chilled blow mold.
• The core rod opens and allows compressed air into the preform, which
inflates it to the finished article shape.
Mailbox post
Insecticide
sprayers

21. Blow Molding
• After a cooling period the blow mold opens and the core rod is rotated to
the ejection position.
• The finished article is stripped off the core rod and leak-tested prior to
packing.
• The preform and blow mold can have many cavities, typically three to
sixteen depending on the article size and the required output.
• There are three sets of core rods, which allow concurrent preform injection,
blow molding and ejection.
Dust binsPumpkin

22. Blow Molding

24. Blow Molding
Stretch blow molding process:
• In the stretch blow molding (SBM) process, the plastic is first molded into
a "preform" using the injection molding process.
• These preforms are produced with the necks of the bottles, including
threads (the "finish") on one end.
Storage shed
Tool cases

25. Blow Molding
Stretch blow molding process:
• These preforms are packaged, and fed later (after cooling) into a reheat
stretch blow molding machine.
• In the SBM process, the preforms are heated (typically using infrared
heaters) above their glass transition temperature, then blown using high
pressure air into bottles using metal blow molds.
Patio blocks
Portable
spa

27. Blow Molding
• The preform is always stretched with a core rod as part of the process.
• In the single-stage process both preform manufacture and bottle blowing
are performed in the same machine.
• The stretching of some polymers, such as PET (polyethylene teraphthalate)
results in strain hardening of the resin, allowing the bottles to resist
deforming under the pressures formed by carbonated beverages, which
typically approach 60 psi.
Snow board
Hockey stick

28. Blow Molding

29. Blow Molding
• The main applications are bottles, jars and other containers.
• Advantages of blow molding include: low tool and die cost; fast production
rates; ability to mold complex part; produces recyclable parts
• Disadvantages of blow molding include: limited to hollow parts, wall
thickness is hard to control.
Spa pillow

30. Blow Molding
Seats of tricycles
Boat fenders
kayaks

31. Blow Molding
Copier tonner bottle
Totes
Hosiery forms
Mannequin parts

32. Blow Molding
• It is usually a requirement that the blown container is rigid, and rigidity
depends on wall thickness among other factors.
• We can relate wall thickness of the blown container to the starting extruded
parison, assuming a cylindrical shape for the final product.
• There is also an effect of die swell on the parison.
• The mean diameter of the tube as it exits the die ‘Dp’ is determined by the
mean die diameter ‘Dd’.
• Die swell causes expansion to a mean parison diameter.

33. Blow Molding

34. Blow Molding
• At the same time, wall thickness swells from td to tP .
• The swell ratio of the parison diameter is given by:
• While the swell ratio for the wall thickness is:

35. Blow Molding
• The swelling of the wall thickness is proportional to the square of the
diameter swelling; that is
• Therefore,

36. Blow Molding
• When the parison is inflated to the blow mold diameter Dm with the
corresponding reduction in wall thickness to tm and assuming constant
volume of cross section, we have
• Solving for tm we obtain:

37. Blow Molding
• Substituting the values of DP and TP :
• The amount of die swell in the initial extrusion process can be measured by
direct observation; and the dimensions of the die are known.
• Thus, we can determine the wall thickness on the blow-molded container.

38. Blow Molding
• Given the wall thickness of the molded container, an expression can be
developed for the maximum air pressure that avoids bursting of the parison
during inflation.
• An equation borrowed from strength of materials relates stress to internal
pressure ‘p’ in a pipe, given its diameter D and wall thickness t:

39. Blow Molding
• Reasoning that the maximum stress will occur just before the parison is
expected to the size of the blow mold diameter (this is when ‘D’ will be
maximum and ‘t’ will be minimum), and rearranging equation to solve for
‘p’, we get

40. Blow Molding
• Where p=air pressure used during blow molding, Pa (lb/in2):
• σ= maximum allowable tensile stress in the polymer during inflation, Pa
(lb/in2) ; and
• t and D are wall thickness and diameter, respectively, of the molding, m
(in.).
• The difficulty in using the formula is in determining the allowable stress
since the polymer is in a heated and highly plastic condition.
• In an industrial operation, the process parameters are tuned by trial and
error.

41. Blow Molding
• Assignment
• Marks: 05 (Lab)
• Submission date: 24-09-2014
• Write the names of the industries along with products relying on blow
molding process for the packaging of their products.