8 Blow Molding

8.1 Processes

The different processes of blow molding, namely extrusion blow molding, injection blow
molding and stretch blow molding are illustrated in the Fig. 8.1 to 8.4 [1], [2], In Fig. 8.5
[2], in addition to the aforementioned processes the principle of dip molding is briefly
explained.

8.1.1 Resin-dependent Parameters

Melt Temperature and Pressure

Typical values of melt temperature and melt pressure for extrusion blow molding are
given in Table 8.1.

Table 8.1: Melt Temperature and Pressure for Extrusion Blow Molding
of Some Polymers

Material Melt temperature Melt pressure

0
C bar
PE-LD 140/150 100/150
PE-HD 160/190 100/200
PP 230/235 150/200
PVC-U 180/210 100/200
PVC-P 160/165 75/150
 PRESS
PLATEN

Parison being extruded

Compressed air inflates

parison

Blown container
being ejected

Fig. 8.1: Extrusion blow molding [1]

 Injecting preform Blow molding and ejection

Fig. 8.2: Injection blow molding [1]

1 2 3

4 5 6

Fig. 8.3: Extrusion stretch blow molding [2]

 Inject preform Reheat preform

Stretch blow molding and

ejection

Fig. 8.4: Injection stretch blow molding [2]

Parison Swell
The wall thickness of the molding is related to the swelling ratio of the parison. Referring
to Fig. 8.11 [3] the swelling thickness of the parison is given by
Bt = y h d (8.1.1)
and the swelling of the parison diameter
Bp = D1ZD, (8.1.2)
Using the relationship [4]
B t = B2p (8.1.3)
it follows
K = K-K
The swell ratio Bp depends on recoverable strain [4], and can be measured.
 extrusion OPEN-ENDED enclousc in mould
PLASTICS MOULDED EXTRUSION BLOW
TUBE
FEEDSTOCK Mow, cool ARTICLE MOULDING
(PARISON)
enclose in first PREFORM transfer to second
(preform) mould. (CLOSE-ENDED (article) mould, EXTRUSION
MOULDED
TUBE WITH STRETCHJ3LOW
blow stretch and blow, ARTICLE
(possibly cool) FULLY FORMED cool MOULDING
NECK)

injection PREFORM transfer to second

moulding (CLOSE-ENDED (article) mould,
PLASTICS MOULDED INJECTION
FEEDSTOCK TUBE WITH blow, cool ARTICLE BLOW MOULDING
FULLY FORMED
NECK)
transfer to second(article)
mould, MOULDED INJECTION
(ORIENTED) STRETCH_BLOW
blow, cooT
ARTICLE MOULDING

dip mandrel into melt PREFORM puo3ds O) JajsuBjj

extrusion in cavity (CLOSE-ENDED
pjnoui (appJB)
PLASTICS HOT MELT MOULDED DIP (DISPLACEMENT)
FEEDSTOCK or injection IN CAVITY complete shaping of TUBE WITH blow, coot ARTICLE BLOW MOULDING
preform round mandrel FULLY FORMED
by piston push on melt NECK)

Fig. 8.5: Sequence of operations in different blow molding processes [2]

Average parison swell for some polymers is given in Table 8.2 [I].

Table 8.2: Average Parison Swell for Some Polymers [1]

Polymer Swell
%
PE-HD (Phillips) 15/40
PE-HD (Ziegler) 25/65
PE-LD 30/65
PVC-U 30/35
PS 10/20
_PC I 5/10

Processing Data for Stretch Blow Molding

Table 8.3: Data on Stretch Blow Molding for Some Polymers [1]

Polymer Melt temperature Stretch orientation Maximum stretch

0
C temperature 0C ratio
PET 250 88/116 16:1
PVC 200 99/116 7: 1
PP 170 121/136 6: 1
PAN 210 104/127 9:1

Volume Shrinkage

Table 8.4: Volume Shrinkage of Stretch Blow Molded Bottles (Seven Days at 270C) [1]

Type of bottle I Percent

Extrusion blow molded PVC
Impact-modified PVC (high orientation) 4.2
Impact-modified PVC (medium orientation) 2.4
Impact modified PVC (low orientation) 1.6
Non-impact modified PVC (high orientation) 1.9
Non-impact modified PVC (medium orientation) 1.2
Non-impact modified PVC (low orientation) 0.9
PET 1.2
Choice of Material

Table 8.5: Data for Choosing Blow Molding Materials [8]

Polymer Appearance in blow Cost for equivalent stiffness

molded form (PE-LD=IOO)
High-impact PVC-U clear high gloss 104
PE-LD transculent, high gloss 100
Low-impact PVC-U very clear, high gloss 87
High-impact PP rather opaque, low gloss 79
PE-HD rather opaque, low gloss 76
Low-impact PP transculent, moderate gloss 71

8.1.2 Machine Related Parameters

Blow Molding Dies

As the parison is always ejected downward and the position of the extruder being
generally horizontal, the term cross-head dies may be applied to blow molding dies. These
can be of the spider type (Fig. 8.6) [5] or side fed dies as shown schematically in Fig. 7.26
[6]. As mentioned earlier, these dies can be designed by using the equations given in
Section 7.3.1.
The interaction of various factors influencing blow molding operations is presented in
Figs. 8.7-8.9 [7] and Fig. 8.10 [8]. Data on air blowing pressures and temperatures for
cavities in blow molds are given in Tables 8.6 and 8.7 respectively.

Table 8.6: Data on Air Blowing Pressures [1]

Polymer Pressure
bar
Acetal 6.9/10.34
PMMA 3.4/5.2
PC 4.8/10.34
PE-LD 1.38/4.14
PE-HD 4.13/6.9
PP 5.2/6.9
PS 2.76/6.9
PVC-U 5.2/6.9
ABS 3.4/10.34
Table 8.7: Recommended Temperature for Cavities in Blow Molds [1]

Polymer Temperature
0
C
PE and PVC 15/30
PC 50/70
PP 30/60
PS 40/65
PMMA 40/60

Extruder
Elbow joint

Tip of Mandrel

Spider legs

die body

mandrel

die ring

parison

Fig. 8.6: Application of spider die in blow molding [3]

Botle Bottle Poylmer
wegi ht weg
i ht die
De
i swell
swell
Metl temperature Poylmer de
i swell De
i land length

Output Output Output

Wal thickness Metl temperature Bo

l wn
i g pressure

Cricum- Critical Parison

ferential shear draw-
wail rate down
thci kness (sag)
variation
Extrusion rate Die gap Melt index

Parison Parison Parison

draw- draw- draw-
down down down
(sag) (sag) (sag)

Extrusion rate Parison weight Parison formation time

Pinch Pinch Die

off off lines
proper- proper-
ties ties Parting
line

Melt temperature Melt index Blowing pressure

Fig. 8.7: Relationship between machine and material

variables in extrusion blow molding process [7]
 Mold temperature
k
Degree Jthicicness Injection Pressure Compo-
of orien- pressure loss nent f.w.
tation in Packing through impact
mod ln
ig time gate strength
Melt
temperature
Melt temperature Melt temperature

With flow
Shrn
i kage Part Molding
weight gloss
Across flow

Mold temperature Packing time Melt temperature

Mold temperature

Component Shrinkage With flow Cooling

Z
IOD time
m
i pact Across flow
strength
aol ng line
of flow
Melt temperature Cavity thickness Packing time/pressure

Restricted gate
Denstiy of Neat Shrinkage
crystaline distortion
poylmers temper- Open gate
ature

Mold temperature Melt temperature Packing time

Long flow
Unti modl path Denstiy Wedl
ca
l mpnig of crys- tensile
pressure talline strength
Short poylmers
flow path
Cavity thickness Distance from gate injection pressure

Fig. 8.8: Relationship between machine and material

variables in injection blow molding process [7]
 Cold mold
Hot mold Along line of flow
Post molding Pressure Impact
shrinkage loss strength
of Annealed through
crystalline gate Across line of flow
polymer
Ageing time Gate area Melt temperature

Weld Shrinkage Cooling

tensile in line time
strength of flow

Distance from gate Gate area Cavity thickness

Density of Flexural Differen-

crystalline and tial
polymers tensile shrinkage
strength
in line
of flow
Cavity thickness Melt temperature Melt temperature

Cavity Density Heat

pressure of distortion
crystal- temper-
line ature
polymers

Packing time Melt temperature Packing pressure

Restricted
gate Along line of flow
Shrinkage Pressure Impact
loss strength
through
Open gate runner Across line of flow

Cavity thickness Injection rate Mold temperature

Weld
tensile
strength

Metl temperature

Fig. 8.9: Relationship between machine and material

variables in injection blow molding process
 STIFFNESS

DENSITY IN g / c m J

Variation of stiffness with density for polyethylene

THICKNESS FOR EQUIVALENT STIFFNESS

DENSITY IN g/cmJ

Relationship between thickness for equivalent stiffness

and density for polyethylene
COST FOR EQUIVALENT STIFFNESS

DENSITY IN g/cm1

Relationship between cost for equivalent stiffness and

density for polyethylene

Fig. 8.10: Relationship between product stiffness, material

density and cost in blow molding process [8]
 D
P

molding

Dm
mold

Fig. 8.11: Wall thickness of parison and molding in blow molding [3]

Literature

1. Rosato, D. V., Rosato, D. V.: Plastics Processing Data Handbook, Van Nostrand-Reinhold,
New York 1990
2. Titow, W.V.: PVC Technology, Elsevier Applied Science Publishers, London 1984
3. Morton-Jones, D.H.: Polymer Processing, Chapman and Hall, New York 1981
4. Cogswell, F.N.: Polymer Melt Rheology, John Wiley, New York 1981
5. BASF Brochure on Blow Molding 1970
6. Michaeli, W.: Extrusion Dies, Hanser, Munich 1992
7. Rosato, D. V., Rosato, D. V.: Injection Molding Handbook, Van Nostrand-Reinhold, New
York 1986
8. Glyde, BS.: Blow Moulding in Thermoplastics, Effects of Processing, Ed. R.M.
Ogorkiewicz, Gliffe Books Ltd, London 1969