PETpla.net Insider 05 / 2020

BOTTLE MAKING PETplanet Insider Vol. 21 No. 05/20 www.petpla.net 42 One-step double layer moulding process for ISBM containers Nissei ASB Machine Co., Ltd. announced the introduction of a new moulding process that further enhances the versatility of its line-up of one-step 4-station injection stretch blow- moulding machines to provide ecological and aesthetic container manufacturing solutions. Moulding process Previously, multi-layer preform moulding has been used to improve container performance by inserting a thin layer of a secondary material between two outer body layers of the preform. ASB’s newly developed double layer moulding process (patents pend- ing) enables the con- tainer to be moulded with an inner and outer layer in the body section (Fig. 1) in a variety of thicknesses, configu- rations, moulding order, or resins as required to provide additional value and flexibility to the standard one-step ISBM process. This method broadens container moulding options in food safety, function and design. It encour- ages increased manufacturing of ecological containers utilising recycled PET resin. Fig. 2 ASB-12N/DL prototype machine for double layer moulding To enable this double layer mould- ing method, ASB has developed a prototype machine designated the ASB-12N/DL (Fig. 2) that is similar in size to its existing small-scale ASB- 12N/10 4-station injection stretch blow-moulding machine. This newly developed machine consists of five stations, with a second injection mould occupying the additional station being supplied by its own injection unit (Fig. 3). The ASB series one- step moulding process is known for its versatility in moulding high quality containers in a vast range of mould- ing resins – now with the addition of the double layer moulding process. The possibilities open up of enhancing either the visual or physical properties using different materials for inner or outer layers. Ecological container – using recycled PET, flake PET Current production of food grade container using recycled PET is lim- ited in many countries due to food safety regulations. By moulding a con- tainer where the inner layer is virgin PET resin, food safety can be assured even while moulding the outer layer with lower quality recycled resin (Fig. 4). The result is the ability to expand the use of recycled resin to a wider range of applications to reduce pollution and preserve resources. Air-less pump container An air-less pump container can increase the pre- and post-retail shelf- Fig. 1 Cross section Fig. 3 Simplified view of double layer moulding concept with cross section of preform & bottle Fig. 4 & 5: Double layer container with recycled material as exterior layer (left) and double layer bottle moulded with collapsible PP liner & PET outer layer