PET-LINE:Top quality preforms

Refreshing all along the line.

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New applications are constantly being developed that lead to increased requirements in terms of the injection process.

Netstal has always seen the diversity of applications and demand for high performance as a new challenge. As such, the proverbial Swiss quality has become a typical characteristic ofNetstal-Maschinen AG.

Throughout the world, Netstal injection moulding machines are synonymous with speed, precision, reliability, user-friendliness and cost-efficiency.

These attributes have also helped Netstal build up a first-rate reputation as a supplier of complete production systems. Typical domains in which our company is active include areas such as the manufacture of bottle caps, packaging, optical discs and complex technical parts.

Netstal is also noted for its specialist competence in the manufacture of preforms for PET packaging. The company is one of the leading suppliers thanks to its PET-LINE production system, which offers pioneering performance features and creates the optimal conditions for a high degree of production efficiency.

Quality from a top supplier

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Platform strategy

The basic PET-LINE concept forms a clearly defined platform strategy. The major benefit: the customer is consequently able to configure each system to meet respective individual requirements and capacity utilisation.

We currently offer three platforms with clamping forces of 2000, 3500 and 6000 kN, which can be combined with a variety of moulds or cavity sizes. The decisive customer benefit: minimum production costs at maximum output.

Platforms with 2000, 3500, and 6000 kN clamping forces

Between 24 and 192 cavities

Individual production system configuration

High output, minimal costs

Optimised: machine sizeMaximised output with the smallest possible machine size. The three system sizes can be equipped with between 24 and 192 cavities. The benefit: individual and requirement-optimised configuration of each system.

Cost-effective: PET-LINE 2000 with 24-cavity mouldDespite the fact that this PET-LINE is based on a platform with a 2000 kN clamping force, effectively making it significantly smaller than its 3500 und 6000 kN sister models, the system offers first-class performance and an optimal price-performance ratio when used with 24, 32,48 and 60 cavity moulds.

Rugged: constructionExceptional precision in terms of all the cavities and absolute accuracy in preform reproducibility is ensured through the solid and robust construction.

PET-LINE 2000-3700R PET-LINE 3500-3550RPET-LINE 3500-6600R PET-LINE 6000-6600R

Thre

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ize

ø 30

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24 32 48 60 48 56 64 72 96 128 96 128 144 192

Mould cavities

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The new ergonomically designed and machine mounted operating unit.

The expansive mould compartment accommodates up to 192 cavities.

Innovative: injection unit with melt shooting potAn optimised 95-mm screw enables continuous plasticizing to produce a gentle melt and low acetaldehyde values. The melt is then transferred to the shooting pot, thereby significantly reducing injection and cycle times.

Cost-efficient: energy consumptionFurther optimisation in terms of details and reductions in machine and mould cooling water consumption has also reduced the specific energy requirement: yet another plus point that distinguishes the Netstal PET-LINE as a highly cost-efficient system solution for manufacturing PET preforms.

Individuality in overview

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Pure high-tech:Perfect transfer of the removal process from the transfer station to the cooling block.

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Cooling block with four cooling positions

Transfer unit

Transfer- and Cooling Unit

Moving platen

Removal gripper

Removal unit

Injection mould

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The fact that the PET-LINE became a high performance system is primarily down to the amalgamation of various individual systems. Typical qualities that are standard for all Netstal ranges such as speed, precision, reliability and user-friendliness were consistently applied. The PET-LINE is also in line with the

The fact that the preforms remain inthe cooling system for 5 cycles ensurestension-free cooling.

Supported by the intrusion program, the plasticizing process is equipped to provide gentle melt preparation, high output and low acetaldehyde values.

contemporary trend when it comes to energy consumption: specifically in terms of the screw drive, screw geometry, clamping unit and robotics sub-assemblies, the PET-LINE achieves minimal energy consumption ratios. The bottom line – PET-LINE achieves an almost unbeatable level of operating efficiency.

High performance, low energy

Cooling (diagram):

Removal gripper cooling and the four subsequent cooling block cycles guarantee tension-free preform cooling.

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In top (pre)form

Unrestricted preform quality; in other words, precise geometric dimensions, low AA values and a first-rate surface structure.

Weight deviation (example with 192 cavities)27.00

26.70

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0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

Cavity

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n g

Minimal: 26.49 gMaximal: 26.67 gDeviation: 0.18 gAverage: 26.58 g

Cavities

Nominal weightTolerance +/– 0.3 g

Weight consistency (over 40 shots for two cavities)26.80

26.50

26.20

0 5 10 15 20 25 30 35 40

Shot

Wei

ght i

n kg

Minimal: 26.33 gMaximal: 26.37 gDeviation: 0.04 g

Cavity 1Cavity 2

Nominal weightTolerance +/– 0.3 g

The PET-LINE production system comprehensively meets all of these criteria – in short cycle times and with an extremely low reject quota.

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Taste neutralThe high-performance screw ensures gentle melt preparation. As a consequence, PET-LINE achieves low AA values, which in turn positively affects the taste neutrality of the subsequent PET bottles. “Mineral water standards” are also achieved with larger cavity numbers.

Always identicalA high level of process reproduci-bility and the consequently, practi-cally homogeneous and perfect preform weight distribution ensure a cost efficient manufacturing process.

Top cycle timesRapid, mechanical processes and optimal coordination between the machine and periphery equipment produce excellent cycle times. In comparison with other systems, the PET-LINE achieves genuine peak values.

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Efforts to reduce cycle times are particularly relevant for production systems operating on a mass production basis, as is the case in the packaging sector, for example. Another related sector is that of PET bottles made from preforms. Until recently, efforts to reduce cycle times had reached their limits. Although optimal and intensive cooling of the preforms helped to shorten the cycle time, the moulded part was often then re-warmed by residual preform heat, specifically in the case of wall thicknesses greater than around 2.5 mm.

The consequence was re-softening, which ultimately lowered the quality of moulding. To avoid this, intensive and continuous post-cooling is extremely important, which is where the patent-pending Calitec® system from Netstal comes in. This system uses compressed air to put slight pressure on the inside of the preform during the post cooling phase, which prevents the moulded part from shrinking by pressing the part evenly onto the cooling

sleeve. In addition, the cooling process is not interrupted and the preform shape is calibrated.The inflation problem is effectively countered by using air to cool the area around the preform shaft, which should not come into contact with the cooling sleeve. Through a special cooling sleeve construction, a steady stream of air is blown around the circumference of the preform where the cone starts, that is, onto the hottest part. This stream of air travels over the surface towards the thread and keeps the “outer skin” rigid – rigid enough to resist the calibration pressure. The upshot of this continuous pressing of the preform is significantly more homogeneous and intensive cooling and superlative moulding.

Since 2007, the Calitec® system has been undergoing long-term trials in order to record the sustainability of the new technology, and the results are pleasing. The customer taking part in the field test was able to report improved preform geometry as well as a 10% increase in productivity.

A breath of fresh air with Calitec®

Calitec® field testingPreform in the cooling sleeve during the post-cooling phase

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As such, we offer support in, for example:

selecting the right system partner and subsequent configuration,

achieving optimal utilisation of the space available,

establishing the ergonomic organisation of the facility

a fully functional machine park.

Production of PET preforms involves a lot more than the mere acquisition of a production system. Most of the time, this entails complete system parks and the cost-effective design of such. A special service within the scope of the ‘Netstal Support Concept’ (see the following pages) offers consulting and support in the conception and optimisation of machine parks. The experts from NSC Plant Consulting provide know-how and experience on how to obtain maximal productivity from machines and periphery equipment.

NSC Plant Consulting

Optimal utilisationBest possible utilisation of the available space increases both productivity and cost-effectiveness.

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Down to the smallest detailNSC Plant Consulting suports you in the detailed planning and development of your production operation.

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Increasing complexity also means a greater customer requirement for services relevant to machine sales. Netstal recognised this need at an early stage and brought all these aspects together under the ‘Netstal Support Concept’ umbrella brand. Important components of the brand are the continuous research anddevelopment work, pre-sales and after-sales service, and training seminars.

Support during project realisation is afforded just as much importance as application technology consulting, quick processing of

spare parts orders and rapid delivery. Short communication channels and well-qualified service technicians guarantee an optimal and customer friendly service. Our specialists’ professional know-how and our international network of prestigious partners enable us to take care of our customers comprehensively and competently.

As a consequence, each year hundreds of manufacturers all over the world benefit from first-rate, project-related consulting, professional training and rapid service provision.

Netstal Support Concept

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Consulting and project planning overview:

Expert consulting Precise project management Implementation of cost-efficient solutions Technology leader in plastic processing Global network of prestigious partners

Customer service overview:

Worldwide distribution and service network Highly experienced and qualified service

professionals Rapid on-site problem resolution Highly flexible assignment structure Short communication channels

Ongoing training

Spare parts service overview:

24/7 spare parts ordering service Global delivery within 48 hours; 24 hours in Europe State-of-the-art spare parts warehouse Part evaluation through proven specialists Worldwide coordination of spare parts available

within the Netstal group

Training overview:

Numerous training modules in a variety of languages Progressive infrastructure and interactive training

methods Diverse seminars on application technology themes Special training teams for optical disc and PET-LINE

customers Various training locations in addition to the

headquarters in Näfels

A tightly knit global distribution and service network with ten subsidiaries and numerous agencies guarantee customer care and rapid service in around 40 countries. More information at www.netstal.com.

Progressive infrastructures and interactive training methods offer the optimal prerequisites for targeted individual training.

In Netstal’s own laboratories, research is carried out on the new and further development of products and optimisation of application technology processes.

Our core expertise has always been the construction of high performance and high precision injection moulding machines. We have been exclusively developing and manufacturing these high-tech products for the global plastics market for more than six decades.

Thanks to a wealth of experience, Netstal has constantly proved itself as a pioneer for the entire sector and has consistently raised the benchmark with groundbreaking innovations.

Netstal machines are all characterised by precision, speed, reliability, user-friendliness and cost-efficiency.

NSC

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Netstal-Maschinen AG 8752 Näfels / Switzerland

Phone + 41 55 618 61 11 Fax + 41 55 618 66 05 Internet www.netstal.com E-Mail pet-line@netstal.com

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Values and foresight

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