Consistently high PET bottle quality with the Intelliblower
The look and feel of the bottle is what ultimately affects how your customers perceive your brand. That’s why Sidel Matrix™ blowers strive to create the very highest PET bottle quality and performance.
Until recently, PET bottle blowing quality control involved frequent sampling and laboratory testing of bottles followed by manual process adjustments. As any manufacturer will confirm, this lengthy process considerably reduces line efficiency because a certain quantity of out-of-tolerance bottles could be produced anyway. Moreover, as bottles get lighter, the blow moulding process has become increasingly important as poor or irregular material distribution negatively affects quality on the entire production line and can even lead to total production shutdown. With the Intelliblower, the Sidel self-regulation blowing system, bottle quality and strength are consistent regardless of bottle weight. This gives producers peace of mind that their brand will appear exactly as intended on the shelves at the store.
Uniformly high quality
The pre-blow phase parameters strongly impact final material distribution. By controlling them instead of just focusing on heating regulation, the Sidel Intelliblower has a stronger impact on production uniformity and packaging quality. The system is self-regulating and blowing processes automatically adapt to maintain an even material distribution with only minor variation.
The machine automatically detects and corrects process deviations on the bottle being blown so each milligram of PET is correctly allocated on the bottle shape. With control at this level, the material is optimally and cost-efficiently used.
Not only does the Intelliblower reduce waste, but when combined with packaging expertise and process capability, it also offers great PET lightweighting potential, even with recycled PET.
A responsive regulation
On a traditional production line,deviations of material distribution on the bottles are often caused by the wrong blowing pressure in an individual blowing station; through incorrect component calibration; or because of wear and tear on mechanical components. The Sidel self-regulation system avoids these deviations by analysing and controlling the blowing curve on each individual bottle. This leads to accurate and consistent distribution with a closed loop on each blowing curve, and adjustment of precise critical points during the pre-blow phase. This process regulation is managed in a very responsive way by using decentralized and more reactive automation allowing a faster and more qualitative exchange of information. Only five consecutive bottles will be produced at that blowing station before the correction is validated. For manufacturers, this self-regulation means less testing and control, and higher quality.
Simple self-regulation of the blowing curve
Designed to be user-friendly, operation is based on a continuous and automatic process regulation with no need for manual intervention. This regulation is applied to three main parameters: pre-blow start, pre-blow flow and pressure. The operator defines the blowing process that matches the technical specifications of the bottle and these parameters are used to define the pre-blow reference curve. Then the real blowing curve is systematically self-monitored at each blowing station during bottle production. If it deviates from the reference curve, an automatic correction is triggered.
Finally, referenced and real blowing process phases are aligned in terms of pre-blow timing (start and duration) and the pressure at all the blowing stations. This continuous regulation is performed on all the bottles to ensure specifications are consistently met. With Intelliblower, the standard deviation of material distribution between the different blowing stations can be halved compared with the process performance of a machine with no self-regulation system.
Anticipating any maintenance
All the process values of individual blowing stations are recorded on the pages of the Human Machine Interface (HMI) with dedicated graphs. This gives operators a complete picture of the process performance and alerts them to any potential deviations, highlighting the stations where the out-of-tolerance bottles are blown. With these insights, operators can quickly identify the malfunctioning blowing station and plan any maintenance so it has minimal impact on production. Even if a maintenance need is identified, production still remains qualitative.
The embedded machine intelligence of the Sidel Matrix blower enables high quality safe packaging that meets exact bottle specifications. In addition to the consistent results obtained in the blowing process, the Sidel blower also incorporates unique bottle neck protection in the oven to maintain bottle performance. Furthermore, it lowers labour and control costs significantly by reducing the amount of maintenance or manual operations required. With Intelliblower, manufacturers can enjoy high performance and increased insight into their production equipment. Or in other words, greater performance consistency and better brand value.
With Intelliblower, the standard deviation of material distribution between the different blowing stations can be halved compared with the process performance of a machine with no self-regulation system.