PETpla.net Insider 04 / 2015

PRODUCTS 41 PET planet insider Vol. 16 No. 04/15 www.petpla.net Sidel Matrix Intelliblower: consistent production of high quality PET bottles Sidel has introduced Intelliblower, a new technology that brings control and self-regulation to the blow moulding pro- cess. The patented technology detects and corrects process deviations and ensures higher accuracy in material distribution during the production of PET bottles. Waste is reduced to a minimum, even with recycled material (R-PET). System controls parameters of the pre-blow phase Prior to Intelliblower, quality control during the blowing pro- cess involved frequent sampling and laboratory testing of bottles. This was then followed by manual adjustments to the process. The procedure is lengthy and reduces line efficiency. More importantly, it does not completely remove the possibility that a number of bottles may still be produced outside the accepted tol- erances. Instead of simply focusing on heating regulation, Intel- liblower controls parameters of the pre-blow phase that strongly impact final material distribution. It has therefore a higher impact on uniformity, irrespective of the bottle weight being produced. A very responsive process correction Inconsistencies of material distribution are usually caused through incorrect blowing pressures of individual blowing sta- tions, through wear and tear of mechanical components or by inaccurate component calibration. The self-regulation of the system avoids deviations by analysing and controlling the blowing curve on each individual bottle. This enables accu- rate and consistent material 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 highly responsive automation that allows faster 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 of the process, along with increased bottle quality. Simple self-regulation of the blowing curve Intelliblower is designed to be user-friendly. Its operation is based on 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 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 per- formed on every bottle to ensure each one consistently meets the necessary specification. The standard deviation of material distribution between different blowing stations can be halved compared to a machine without self-regulation. Amount of maintenance significantly reduced Through the Human Machine Interface (HMI) of the Sidel- Matrix blower, process values of individual blowing stations are recorded, along with dedicated graphs. This provides operators with a comprehensive overall picture of the pro- cess performance. It also alerts about potential inconsisten- cies, indicating those stations where bottles are being blown outside accepted tolerances. Malfunctioning stations can be easily identified and maintenance implemented in order to minimise impact on production. www.sidel.com