HyPET Preform Systems

Turnkey solutions for every application and volume

HyPET systems
• Industry-leading productivity

• Highly repeatable and reliable

performance

• Easy-to-use operator
interface

• Energy efficient

• Optional High Performance

Package (HPP)

• Optional Recycled Flake (RF)

capability

• Optional Flex Mold for fast,

easy product and mold
change
• Combining HyPET with Husky
Services ensures customers
achieve the lowest total cost
of ownership over the
product life cycle
• Leading-edge auxiliary
equipment optimized for
Husky systems
Husky has been the leader in the preform
equipment industry for over 35 years with
more than 3 500 systems installed around
the world. HyPET® is our flexible preform
injection molding system capable of pro-
ducing over 110 000 preforms per hour. It
is available in seven sizes, ranging from 90
to 650 tonnes (100 to 715 tons) for molds
between two and 192 cavities.
All components of the HyPET system,
including the hot runner, mold, machine,
robot and post-mold cooling, are spe-
cifically designed to work together as a
fully integrated workcell to achieve the
industry’s highest levels of productivity
and quality. In addition, we offer a diverse
range of services, including preform devel-
opment, preform prototyping, preform
lightweighting, mold conversions and mold
refurbishing.
For customers looking for a turnkey solu-
tion for preform production, Husky is the
single point of contact for plant design,
the complete injection molding system,
the auxiliaries and downstream product
handling equipment from our industry
partners.
 HyPET features/overview
HyPET systems located at a customer plant in Moscow.
Better cooling for faster cycles
HyPET uses an integrated part cooling and
handling system called CoolPik®, which
features up to four cycles of balanced
cooling on the preform’s inner and outer
surface. This results in faster cycles and
better part quality in comparison to other
post-mold cooling systems that only cool
the outer surface.
2 HyPET Preform Systems
Optimized technology
A wide range of extruders are available to
best match the equipment with the specific
needs of the application. Newly developed
HyFLO plasticizing screws minimize acet-
aldehyde (AA) generation and increase
mixing and plasticizing performance.
Collaborating with industry leaders to
bring the best technology
In addition to our own complete systems,
we work closely with other technology
partners to create innovative solutions.
From barrier systems to recycling technolo-
gies to new materials, we are continually
collaborating with industry leaders to bring
new technologies and products to market.
HyPET features/overview

PET Auxiliary Equipment

When purchasing a new Husky HyPET
system customers can choose Husky PET
auxiliaries that offer leading-edge designs
specifically optimized for Husky systems.

Husky assists customers by coordinating

the integration, testing and delivery of
complete turnkey systems that are opti-
mized for maximum productivity. Husky
is responsible for the complete workcell,
overseeing configuration, supply and
installation, as well as providing complete
support, service and parts complemented
by a comprehensive warranty. Most impor-
tant of all, customers get a single point of
contact to support them in the success of
their products.
By choosing Husky PET auxiliaries, cus-
tomers get a complete, integrated PET
system. This complete solution has mul-
tiple benefits, including improved energy
consumption, enhanced controls interface
and advanced feature capability. Auxiliaries,
including resin dryers, dehumidifiers, chill-
ers and soft-drop part handling, are all
centrally controlled through Husky’s Polaris
Control operator interface. Advantages of
this integration include:
• Control of entire molding system from a
single interface
• Remote connectivity through ServiceLink™
• Integrated alarm handling and notification
for easy troubleshooting
• Assured total process control through SPC
HyPET with High Performance Package
The Husky High Performance Package
(HPP) is the result of refinements to the
entire HyPET preform system, including
mold, robot, injection unit, clamp and
auxiliary equipment. Only through this
coordinated effort has it been possible
to significantly improve molding cycle
times, while still producing preforms with
“In June 2008, Western Container Corporation took on-time delivery of our latest preform
molding system. The 192-cavity Husky Injection Molding System was in production on
schedule. This installation and start-up was one of our best experiences with a preform
system integration in our history. It has cost-effectively expanded our production of a
broad portfolio of preform designs and colors for the Coca-Cola Company.
We now have the world’s highest output preform system resulting from a Western
Container Corporation—Husky collaborative relationship.”
Mike Andrysiak—President and CEO
Western Container Corporation
superior levels of quality. This new tech- negatively influence bottle quality. A new
nology typically reduces cycle times by extruder design enables improved process-
approximately 15% compared to previous ing of pellet and flake blends.
industry-best cycle times.
The HyPET RF option enables molders to
The productivity improvements offered begin using recycled PET or increase the
by HyPET with HPP further reduce the cost percentage used. Preform quality is
of PET packaging, making it even more maintained or even improved, even with
competitive with glass, metal and carton increased recycled PET content. The end
alternatives. result is a molding platform that can lower
the environmental impact of PET as a pack-
HyPET Recycled Flake system aging material without compromising part
The HyPET Recycled Flake (RF) system is quality.
specifically designed for manufacturing
preforms with high percentages of food-
grade recycled PET flake. An integrated
melt filtration system minimizes black
specks and other contaminants that can

HyPET Preform Systems 3

 EcoBase preform lightweighting

Significant lightweighting benefits

EcoBase™ is a uniquely shaped preform
base that differs from the traditional
hemispherical design commonly seen
throughout the industry. By reducing the
wall thickness of the preform base to be
more consistent with the body, the new
shape allows for a weight reduction of the
overall preform by up to 2.5%. This results
in lower costs and a reduced carbon foot-
print.

Preform design optimized for specific

needs
Upon review of the intended produc-
tion equipment, Husky will optimize the
EcoBase preform’s dimensions to meet an
application’s specific blowing and perfor- EcoBase offers up to 2.5% resin savings.
mance requirements. Easy to integrate into
existing molds, EcoBase requires minimal
changes to the preform system. In most Potential weight savings
cases, no hardware changes to the blowing
machine are required. Mineral water Carbonated soft drink
500 ml—up to 0.3 grams 600 ml—up to 0.5 grams
Improved energy utilization during
1.0 liter—up to 0.6 grams 1.5 liter—up to 1.1 grams
reheat
1.5 liter—up to 0.8 grams 2.0 liter—up to 1.2 grams
The EcoBase preform design improves heat
absorption of the preform base during Actual savings depend on original preform weight and dimensions
blow molding. A traditional hemispherical
preform base is difficult to reheat because
most of the infrared energy is reflected off
the surface of the preform instead of being formance, including stress cracking, burst Case study
absorbed. EcoBase provides greater control strength and top load, is consistently equal Application: 1.5 liter, (sparkling water)
of the reheat profile in the preform base to or better than bottles blown from pre- Weight savings: 0.6 grams after base light-
resulting in an improvement of up to 3% in forms with the standard hemispherical weighting
energy absorption during reheat. base shape.
Cavitation 96-cavity
Mechanical performance Weight savings 0.6 grams
During the blow molding process, bottles
Cycle time 9.0 seconds
with the EcoBase preform design demon-
190 tonnes
strate better material distribution in the Annual resin savings
(209 tons)
base of the bottle. This is possible because
EcoBase eliminates the wasted material
typically observed around the injection
point, allowing for an optimized preform
base. Testing has shown mechanical per-

4 HyPET Preform Systems

Preform molds

As the world’s largest moldmaker, Husky Ease of maintenance Preform prototyping

is able to deliver global tooling programs
for new molds or conversions of any size.
Preform molds are produced at dedicated
facilities in Canada, the United States and
Luxembourg. Husky continues to invest in
these state-of-the-art facilities to increase
capacity, reduce lead times and maximize
part quality. In-house test rooms are capa-
ble of testing all molds manufactured.
Husky preform molds are designed and
built to produce the highest quality pre-
forms at the best cycle times in the industry.
Preform molds are available from two up to
192 cavities.
• Connecting bars are driven by a mainte-
nance free cam assembly
• Stainless steel stacks eliminate molding
surface corrosion
Mold refurbishment
Maintaining best-in-class quality pre-
forms requires regular mold maintenance
and scheduled refurbishing programs.
Customers can quickly and easily convert
or refurbish their molds at any location
throughout Husky’s industry-leading net-
work of refurbishing centers.
As part of a conversion or new product
launch, Husky helps customers get new
bottles to market quickly by offering
preform development and prototyping
services. We are uniquely positioned to
develop preform designs that are opti-
mized for production scale molding. When
the preform design is final, we can imme-
diately scale up to a production mold by
transferring the project to our production
team.

Productivity
• Fast cycling due to specially designed
cooling circuits
• Part ejection sensors that monitor preform
transfer to the take-off plate, improving
cycle time
• Standard interchangeable mold compo-
nents; replacement parts available within
24 hours
• Two-piece cavity option allows the re-
placement of wear parts without changing
the entire cavity
Flex Mold
Flex Mold™ is a flexible, low cavitation PET
preform mold. Available in eight, 16 or 24
cavities, Flex Mold is ideal for lower volume
preform producers (producing between
five and 30 million units each year) or those
manufacturers who produce a range of
preform families.

Reliability Flex Mold:

• Rugged design for long life
• Roller cams that actuate both the opening
and closing actions on the thread splits
• Ultra hot runners feature a spring pack
that eliminates resin leakage between the
manifold and the nozzle and longer valve
gate seal life
Part quality
• Lowest cavity-to-cavity weight and dimen-
sional variation as a result of best-in-class
manufacturing machines and processes
• Water hoses that are consolidated at
the bottom of the mold, eliminating the
potential for water marks on preforms
• Reduces mold change times by one third
compared to conventional designs
• Eliminates the need to cool down and
reheat the hot runner during a preform
change
• Minimizes the number of components Flex Mold is ideal for producing families of
that need to be replaced for a new pre- bottles with common threads.
form design
• Includes adjustable cams that can be used • Includes a mold water purge system to
for a variety of preform designs, thereby improve mold change time and reduce
reducing conversion cost water spillage
• Uses post-mold cooling tubes mounted
on lightweight “take-off bars” to eliminate
the need for a crane during take-out plate
changes

HyPET Preform Systems 5

 Broadest product range in the industry

Applications

HyPET 90 HyPET 120 HyPET 225 HyPET 300 HyPET 400

Cavitation Cavitation Cavitation Cavitation Cavitation

output (mm/yr) output (mm/yr) output (mm/yr) output (mm/yr) output (mm/yr)

500 ml (17 oz.)

Carbonated soft drink 24 32 48 72 96
Neck Finish: 28 mm PCO 86.4 112.5 163.0 236.6 312.1
Weight: 21–25 grams

500 ml (17 oz.)

Bottled water 24 32 48 72 96
Neck finish: 26 mm PCF 148.1 197.4 296.2 418.7 547.7
Weight: 10–14 grams

500 ml (17 oz.)

RTD tea / Hotfill 24 32 48 72 96
Neck finish: 28 mm 63.6 84.8 127.3 186.0 246.0
Weight: 23–27 grams

473 ml (16 oz.)

Dairy 24 32 48 72 96
Neck finish: 30–38 mm 63.6 84.8 127.3 186.0 246.0
Weight: 22–26 grams

500 ml (17 oz.)

Aseptic juice 24 24 32 72 96
Neck finish: 38 mm Bericap 81.5 81.5 108.7 236.6 312.1
Weight: 18–24 grams

591 ml (20 oz.)

Hotfill juice 24 24 32 72 96
Neck finish: 38 mm VHS 41.7 41.7 55.6 123.0 163.0
Weight: 29–32 grams

3–5 gal (384–640 oz.)

Water — — 8 16 16
Neck finish: HOD Standard — — 4.8 9.6 9.6
Weight: 300–380 grams

1.5 l (51 oz.)

Sparkling water 24 32 48 72 96
Neck finish: 25–30 mm 77.2 102.9 154.4 224.4 296.2
Weight: 25–36 grams

330 ml (11 oz.)

Beer 24 32 48 72 96
Neck finish: 28 mm PCO 69.7 93.0 139.5 203.4 268.8
Weight: 22–30 grams

946 ml (32 oz.)

Food jar 8 8 16 24 32
Neck finish: 63 mm SP400 16.8 16.8 33.6 49.3 65.3
Weight: 37–40 grams

6 HyPET Preform Systems

 Maximum preform mold cavitations
Maximum thread HyPET HyPET HyPET HyPET HyPET HyPET HyPET
HyPET 500 HyPET 650
diameter 90 120 225 300 400 500 650

Cavitation Cavitation up to 30 mm 24 32 48 72* 96* 144* 192**

output (mm/yr) output (mm/yr)
up to 38 mm 24 24 32 72* 96* 128* 144**

up to 43 mm 16 16 32 48 72 96 144**
144 192
458.3 552.9 up to 48 mm 12 12 24 32 48 72 —

up to 63 mm 8 8 16 24 32 48 —

up to 70 mm 6 6 12 16 24 32 —
144 192
791.7 893.2 up to 90 mm 4 4 8 12 16 24 —

up to 110 mm 2 2 6 8 12 16 —

144 192
* Available in both HyPET and HyPET with High Performance Package (HyPET HPP)
362.8 446.6
** Only available as HyPET HPP

144 192
362.8 446.6

128 144
407.4 414.7

128 144
215.0 229.1

24 —
14.5 —

144 192
435.4 527.8

144 192
395.8 483.8

48 —
96.7 —

HyPET Preform Systems 7

Husky Services
For more than 50 years, Husky has been
building expertise through a knowledge
base that is unmatched in the injection
molding industry. That knowledge can be
accessed through Husky Services.
With Husky Services products and pro-
grams, a customer can develop and
implement a proactive strategy that bal-
ances preventative and predictive elements
—all geared toward achieving industry-
best overall operational effectiveness.
Whether customers opt for a scheduled,
contracted relationship or a pay-as-you-go
model, Husky provides access to experts
through a complete asset management
program comprised of a diverse range of
products and services.
Pro-Act
Tailored specifically for the injection mold-
ing industry, Pro-Act™ is Husky’s premier
proactive maintenance solution that offers
flexible programs to improve asset avail-
ability and performance.
Advisory services
Access Husky’s Service and Support
network to gain in-depth knowledge,
consulting and assessment expertise
Husky Injection Molding Systems
www.husky.ca
Head Office Canada • Tel. (905) 951 5000 • Fax (905) 951 5384
Asia China • Tel. (86) 21 5048 4800 • Fax (86) 21 5048 4900
Europe Luxembourg • Tel. (352) 52 11 51 • Fax (352) 52 60 10
Made from chlorine-free bleached pulp. Please recycle. 10-015 March 2010
throughout all levels of the production
process—from equipment level through to
plant level.
Hot runner maintenance
Husky maintenance services provide a
cost-effective solution to ensure optimized
hot runner performance. Services range
from melt channel cleaning to a complete
overhaul—all components are inspected
and those that do not meet original specifi-
cations are replaced.
Mold care
Husky refurbishment services provide a
cost-effective and thorough maintenance
solution to ensure improved productivity,
uptime and longer tool life.
Training
Husky provides comprehensive technical
training programs to support over 25 years
of equipment design. Husky certified train-
ers offer practical courses on a variety of
subjects and work with customers to devel-
op customized programs and schedules to
meet specific requirements.
Productivity and process monitoring
Applicable to both Husky and non-Husky
machines, our flexible monitoring systems
help to improve part quality and increase
output while our software solutions enable
real-time data collection for multiple injec-
tion molding systems.
Product upgrades
Husky works with customers to help mod-
ernize existing equipment to improve
productivity, reliability and functionality.
Spare parts
Husky supports an extensive global parts
and distribution network with the best
availability in the industry.
Third party services
Through our global network of contacts,
Husky is able to assist customers by coor-
dinating the sourcing and delivery of
complete turnkey systems that are opti-
mized for productivity.
® HUSKY, HUSKY KEEPING OUR CUSTOMERS IN THE LEAD & DESIGN, Polaris
and HyPET are registered trade-marks of Husky Injection Molding Systems
Ltd. in the United States and other countries, and may be used by certain
of its affiliated companies under License. Pro-Act, EcoBase, ServiceLink
and other HUSKY products or service names or logos referenced in these
materials are trade-marks of Husky Injection Molding Systems Ltd. and may
be used by certain of its affiliated companies under License.
© 2010 Husky Injection Molding Systems Ltd. All rights are reserved.