1、PET CO-INJECTION SYSTEMSPET CO-INJECTION SYSTEMS KORTEC KORTECCOMPANY HISTORYn1996:Develop technology concepts and file first patent applications Market studyn1997:Design and build prototype system based on 48 cavity modelDevelop process parameters for barrier resinsn1998:Product development program
2、sl2&4 cavity moldsn1999:CommercializelAnheuser Busch beer bottle launchl8-cavity in Januaryl48 cavity molding cell in 2nd quarter 1999WHAT DO CONVERTERS WANT?nOperating efficiency equal to monolayernCycle time equal to monolayernMachine size and mold size equal to monolayernEase of operation and pro
3、cess controlnEconomical use of barrier materials as low as 2%nUniform distribution around leading edge of barriernPreforms with barrier with PCR with PCR and barrierCoreSkin Kortec Melt Delivery SystemGates Kortec Co-Injection NozzlesXXXXTURNKEY PET CO-INJECTION SYSTEMSOTHER TECHNOLOGY3-LAYER FLOWOT
4、HER TECHNOLOGY3-LAYER FLOWOTHER TECHNOLOGYTHREE-LAYER FLOWBIASED FLOW 15%EVENLY DISTRIBUTED FLOWOTHER TECHNOLOGYTHREE-LAYER FLOWv=1.25 vv=1.62 v12lKORTEC TECHNOLOGY3-LAYER FLOWKORTEC TECHNOLOGY3-LAYER FLOWKORTEC TECHNOLOGYTHREE-LAYER FLOWBIASED FLOW 15%EVENLY DISTRIBUTED FLOWKORTEC TECHNOLOGYTHREE-L
5、AYER FLOWlOTHER NOZZLESKORTEC NOZZLESn Combine layers remote from gatel Standard mold sizel Standard machine sizen Combine layers close to cavityl Non-standard mold sizel Non-standard machine sizeWHAT DO CONVERTERS WANT?KORTECANCCPTHofstetter DevtechYESnononoyesoperating efficiency=monolayerYESyesno
6、nonocycle time=monolayerYESnononoyesstd size machine&moldYESnoyesnonobarrier 2%YESyesyesnonouniform leading edgeYESyesyes8%minnopreform with barrierYESyesyesyesnopreform with PCRYESnoyesnonopreform with both3 or 4353&57-13number of layersnPreform/container developmentnComplete turnkey molding celll
7、Husky multi-material molding machinel Husky Generation II preform mold cold halfl Kortec co-injection melt delivery system with patented three-layer nozzle technologyl Husky robotl Husky three position take-out platel Customer specified auxiliary equipmentnProcess optimizationnIn-plant start-upnComp
8、lete trainingKORTEC PET CO-INJECTION SYSTEMSCONTAINER PERFORMANCEnMaterial selection/distribution Skin material Core material%barrierl%thickness of walll Uniformity of distributionl%of area covered/protectednRelative humidity Inside container Outside containernTemperatureBARRIERCONTAINER DEVELOPMENT
9、nShelf Life Analysisl Define effects of oxygen on product l Determine barrier requirementsl Use actual temperature&R.H.rangesnMultilayer Container Modelsl Select skin and core resinsl Determine optimum core distribution and volumel Predict container performancenDesign Program to Produce&Test Samples
10、CO-INJECTION MACHINE CONFIGURATION“Top View”Main injection unit=two-stage“shooting pot”(can be used to operate standard mono-material injection molds)Secondary injection unit=reciprocating screwOperator sideCO-INJECTION MACHINEINJECTION UNIT LOCATIONS Barrier RS unit“reciprocating screw”(off-center/
11、non-operator side)Two-stage PET“shooting pot”(on machine )CLPET PREFORM MOLDSnHusky ADAPT 2&4 cavity development moldsnHusky Generation II production molds are available up to 48 cavitiesnStandard Husky pitch(60mm X 152mm)l Molds fit standard 300 ton machinesl Retrofit existing moldsnCan meet standa
12、rd Husky Index dual and quad face requirements(60mm X 140mm)“INDUSTRY-STANDARD”nCustom Engineeringl Skin and core materialsl Preform sizel Skin and core volumesl Inlet locations matched with machine injection unitsnSeparate manifold blocks for independent temperature controlnHeat pipes for unparalle
13、led temperature uniformitynFlow channels are completely branch balancedKORTEC CO-INJECTION TECHNOLOGYMELT DELIVERY SYSTEMKORTEC THREE-LAYER NOZZLEKORTEC THREE-LAYER NOZZLEnUnique 3-layer Flowl Core on zero gradient of velocity profilel Total control of core distributionl Shot-to-shot and cavity-to-c
14、avity consistencynStandard Mold Constructionl Standard cooling throughoutl Standard cavity spacingl Retrofit existing moldsnValve Gate Controll Pneumatic or hydraulicnComplete System Integration by Kortec in Beverly,MA USAnKortec is Responsible for Complete System PerformanceINTEGRATED SYSTEMnHusky
15、machine efficiency same as monolayernSimple process conceptl Volumetric control using uniform injection speed profilel User friendly software-2 parameters adjust barrier positionl 60 second changeover from one core volume to anothernSelf-cleaning nozzlesl Minimal periodic maintenance(over 50 start-u
16、ps and shut-downs using 5 different barrier resins)HIGHEST OPERATING EFFICIENCYTARGET:95%FOR 48-CAVITY MOLDVELOCITY PROFILEBARRIER EXAMPLE40%60%100%GENERAL FILL SEQUENCEPETOnly PET +BarrierPETOnly0.511.522.533.544.555.56TimeFlow RateBarrier(B)PET(A)AOnlyA&B AOnlyFILL PROFILEBarrier exampleKORTEC CO-
17、INJECTION PROCESSnCycle time is equal to standard PET moldingnStandard Stretch and Blowing ProcessnStandard AA levelsnAs Repeatable as Standard PET MoldingnBarrierl 3-layer(2%to 20%)l Zero-gradient of velocity profilel Controlled distribution of barrierl Controlled distribution independent of inject
18、ion timel Materials:EVOH,MXD6 nylon,oxygen scavenger,developmental nPCRl 3-layer(20%to 40%)nBarrier/PCRl 4-layer up to 35%(e.g.5%&30%)nAll cycle times equal monolayer cycle timeKORTEC PREFORM TECHNOLOGYCORE DISTRIBUTION5-10 times sidewallthickness5-10 times sidewallthicknessControlledKORTEC“SMART-FI
19、LL DISTRIBUTIONCUSTOM FOR EVERY APPLICATIONControlled“leading edge”Uniform layer thicknessEXAMPLE 20 OUNCE C.S.D.BARRIER PERFORMANCE ContainerPermeation RateBarrier EffectStraight PET5-Layer(5%Full)3-Layer(5%Full)3-Layer(4%controlled).1158.0386.0386.0351 PET3.0 X PET3.0 X PET3.3 X PETMULTILAYER vs.M
20、ONOLAYERMATERIAL COST PREMIUM Structure Barrier$PremiumFive-LayerThree-LayerThree-Layer5%Full Coverage5%Full Coverage4%Controlled Distribution20%20%16%nOperating efficiency equal to monolayernCycle time equal to monolayernMost economical use of barrier materialnSimple for machine operatorlchange onl
21、y two parameters to change barrier positionnEasy start-up of systemnIndustry standard machine and mold sizesKORTEC ADVANTAGESCONCLUSIONSnKortec 3-layer preforml Optimized core layer volume and distributionl Better barrier and scavenging propertiesl Less core material needed=less resin premiumnKortec
22、 equipmentl Integrates with industry-standard molding equipmentl Complete process optimization and operator trainingl Turnkey systems are commercially available to 48 cavities!TOTAL SYSTEMS APPROACHnFixed CostsnFastest Lead TimesnSingle Source ResponsibilitynNo Additional Personnel or Expertise NeedednGuaranteed ResultsCo-Injection ExpertiseMaterial Flow Analyses SystemEngineering Integration and TrainingGuaranteed ResultsCo-Injection EquipmentTwo-Color Machine&MoldTOTAL SYSTEMS APPROACH
