Decades after the introduction of injection blow moulding (IBM), a new technique has entered the market that promises to offer higher output, better quality bottles and increased sustainability in an in-line sequence that does not require station-to-station transfer. The new technology means that containers can be produced from pellets to finished product on the same machine.
Compression blow forming (CBF) has been developed by Sacmi, the Italian manufacturing group known for its compression moulded caps. Earlier this year the first CBF machine - a 12-cavity unit that can create monolayer HDPE bottles between 24-33 mm in size - was installed at Amcor's facility in Youngsville, the US.
Amcor has described the machine as a "game changer". Bob Israni, Amcor manager of pharmaceutical project management said: "The whole technology kind of combines to give a superior and better quality product. It's kind of beautiful."
The CBF process operates at lower temperature, typically 30¡C cooler, than IBM. As a result, there is lower residual stress in the end product and improved cycle times because there is less heat to remove after blowing and reduced secondary cooling after takeout. What heat there is gets taken out using an air conditioner and dehumidifier on the machine's conveyor.
The first installation was the result of a 14 month collaboration between Sacmi and Amcor to bring CBF technology to commercial scale in pharmaceutical packaging. In addition to the 12-cavity unit, Amcor hopes to have a 20-cavity unit with the ability to run HDPE, PS, PE and PET - the only technology on the market capable of using the four main resins used in packaging - in operation by the end of the year.
The larger capability unit will be able to produce bottles of 150mm and 300mm in size for use as single-serve dairy product packaging.
A total of four CBF machines will be installed in the US by the end of 2012, with other machines shipped to China, Sweden and emerging economies such as Vietnam.
Machines are equipped with a fully-integrated inline inspection system. Infrared cameras detect surface and internal contamination and leaks can be detected immediately after the bottle is blown. Surfaces are treated using a plasma process rather than flaming to minimise environmental and health and safety risks.
Compression blow forming (CBF) has been developed by Sacmi, the Italian manufacturing group known for its compression moulded caps. Earlier this year the first CBF machine - a 12-cavity unit that can create monolayer HDPE bottles between 24-33 mm in size - was installed at Amcor's facility in Youngsville, the US.
Amcor has described the machine as a "game changer". Bob Israni, Amcor manager of pharmaceutical project management said: "The whole technology kind of combines to give a superior and better quality product. It's kind of beautiful."
The CBF process operates at lower temperature, typically 30¡C cooler, than IBM. As a result, there is lower residual stress in the end product and improved cycle times because there is less heat to remove after blowing and reduced secondary cooling after takeout. What heat there is gets taken out using an air conditioner and dehumidifier on the machine's conveyor.
The first installation was the result of a 14 month collaboration between Sacmi and Amcor to bring CBF technology to commercial scale in pharmaceutical packaging. In addition to the 12-cavity unit, Amcor hopes to have a 20-cavity unit with the ability to run HDPE, PS, PE and PET - the only technology on the market capable of using the four main resins used in packaging - in operation by the end of the year.
The larger capability unit will be able to produce bottles of 150mm and 300mm in size for use as single-serve dairy product packaging.
A total of four CBF machines will be installed in the US by the end of 2012, with other machines shipped to China, Sweden and emerging economies such as Vietnam.
Machines are equipped with a fully-integrated inline inspection system. Infrared cameras detect surface and internal contamination and leaks can be detected immediately after the bottle is blown. Surfaces are treated using a plasma process rather than flaming to minimise environmental and health and safety risks.
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