02/03/2015
The patented technology ensures greater accuracy in distribution of material during the production of individual bottles, with the elimination of inconsistencies resulting in improved quality, regardless of bottle weight.
Bottle quality affects brand perception
The blow moulding process is becoming increasingly important as the drive for ultimate lightweighting of PET bottles within the industry continues. Poor or irregular material distribution within the production of bottles can adversely affect quality throughout the entire process and can even lead to a total shutdown of the line. Because the appearance and handling of the bottle is what ultimately affects how any brand is perceived, Sidel is continually striving to create the highest quality and performance possible in PET bottles. With the new Sidel Matrix™ blower, Sidel is challenging the conventions of production and manufacturers can rest assured that their beverage brand will consistently appear on the shelves exactly as they intended. With the introduction of Intelliblower, Sidel is also leading the way in blow moulding performance with this unique patented blowing process control and self-regulation system.
Embedded intelligence enables improved quality
Prior to Intelliblower, quality
control for PET bottle blowing involved frequent sampling and
laboratory testing of bottles. This was then followed by manual
adjustments to the process. The procedure is lengthy and
considerably reduces line efficiency. More importantly though, it
does not completely remove the possibility that a number of bottles
may still be produced outside accepted tolerances. By controlling
parameters of the pre-blow phase that strongly impact final
material distribution instead of simply focusing on regulation of
heating, the Sidel Intelliblower uses PET material optimally and
cost efficiently. It is therefore able to have a higher impact on
production uniformity and packaging quality, irrespective of the
weight of the bottle being produced.
Self-regulating, the Intelliblower system automatically detects
and corrects process deviations on the shape of each bottle being
blown, adapting to maintain an even material distribution with only
the most minor variations. This ensures that every milligram of PET
is correctly allocated. With control of this level combined with
the packaging expertise and process capability of the Sidel
Intelliblower, waste is reduced and excellent PET lightweighting
potential is possible, even with recycled material (R-PET).
A very responsive process correction
Inconsistencies of material distribution within the bottles are
usually caused through incorrect blowing pressures of individual
blowing stations, by inaccurate component calibration or through
wear and tear of mechanical components. The self-regulation of
Sidel Intelliblower avoids these deviations by analysing and
controlling the blowing curve on each individual bottle. This
produces accurate and consistent distribution with a closed loop on
each blowing curve and adjustment of critical points during the
pre-blow phase. This process regulation is managed in a
responsive way by using decentralised and more responsive
automation that allows faster and better exchange of information.
As a result, only five consecutive bottles are produced at a
blowing station before the necessary correction is validated. This
self-regulation means far less sampling, testing and adjusting for
producers, along with increased bottle quality.
Simple self-regulation of the blowing curve
Sidel Intelliblower is designed to be
user-friendly. Its operation is based on continuous and automatic
process regulation without the need for any manual intervention.
This regulation is applied in three areas: pre-blow start, pre-blow
flow and pressure. The line operator defines the blowing process
that matches the technical specifications of the desired bottle
shape 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 actual production of
the bottles. If blowing deviates from the reference curve, a
correction is automatically implemented. 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 every bottle to ensure
each one consistently meets the necessary specification. With
Sidel's Intelliblower, the standard deviation of material
distribution between different blowing stations can be halved when
compared to a machine without self-regulation.
A perfect way to anticipate maintenance
Through the Human Machine Interface (HMI) of the Sidel Matrix blower, process values of individual blowing stations are recorded, along with dedicated graphs. This gives operators a comprehensive overall picture of the process performance. It also alerts them to any potential inconsistencies, indicating those stations where any bottles are being blown outside accepted tolerances. They are therefore able to easily identify malfunctioning stations and plan any necessary maintenance in order to minimise impact on production. Even if maintenance is deemed necessary, production generally still remains viable. As a whole, the Sidel Matrix blower is reducing the amount of maintenance and manual operations required, while lowering labour and control costs significantly.
With Sidel Intelliblower, beverage producers are able to enjoy improved bottle quality due to higher blow moulding performance along with an increased insight into the operation of their production equipment. Put even more simply, they will benefit from greater package consistency and subsequently, better brand value.
Sidel is constantly striving to challenge the conventions of PET production and rise above the expectations of beverage producers. For more information on Sidel Matrix blowers, please visit sidel.com/matrix-blower.
Download high quality pictures