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Image(left) - Cross-section of cosmetic bottle molded by the Double Layer Process

Image (right) – ASB-12N/DL prototype machine for double layer molding.


Ecological or Premium Quality ISBM Containers


Nissei ASB Machine Co., Ltd. (Head office: Komoro‐shi, Nagano‐ken, Japan ‐ President: Junichi Miyasaka), a world leading manufacture of machines and molds for injection stretch blow molding of PET and other plastics, wishes to announce the introduction of a new molding process that further enhances the versatility of its line‐up of One‐Step 4‐ Station injection stretch blow molding machinesto provide both ecological and aesthetic container manufacturing solutions.



Image(left) - Double layer food or beverage container with recycled material as exterior layer (only virgin material makes food contact).

Image (right) – Various double layer cosmetic containers, (numbers in parenthesis indicate molding station of resin).


Molding Process


Previously, multi‐layer preform molding 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 molding process (patents pending) enables the container to be molded with an inner and outer layer in the body section (Image 1) in a variety of thicknesses, configurations, molding order, or resins as required to provide additional value and flexibility to the standard One‐Step ISBM process. This method broadens container molding options not only in food safety, function and design but also encourages increased manufacturing of ecological containers utilizing recycled PET resin.

To enable this Double Layer molding method, ASB has developed a prototype machine designated the ASB‐12N/DL (Image 2) that issimilar in size to its existing small‐scale ASB‐ 12N/10 4‐station injection stretch blow molding machine. This newly developed machine consists of five stations, with a second injection mold occupying the additional station being supplied by its own injection unit (Image 3). The ASB Series One‐Step molding process is already well known for its extreme versatility in molding high quality container in a vast range of molding resins – now with the addition of the Double Layer molding process, the possibilities to it is possible dramatically enhance either visual or physical properties using different materials for inner or outer layers.





Image(left) - Extreme thick base jar in PET showing cross-section.

Image (right) – Additional decorative options achievable by double layer molding with extra thick based jar on extreme left and striped containers at center-right.


Applications


    The molding concept has already produced a range of additional applications including;
  • Ecological container – Using recycled PET, flake PET Current production of food grade container using recycled PET is limited in many countries due to food safety regulations. By molding a container where the inner later is virgin PET resin, food safety can be assured even while molding the outer layer with lower quality recycled resin (Image 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‐life of various food products. A collapsible inner layer comprising of a suitable resin is formed during container molding (Image 5). As the product is pumped out, the inner layer separates and shrinks away from the outer layer to ensure that no headspace develops over the product, minimizing its contact with oxygen and preserving the contents even after initial opening.
  • Moisture barrier container By using PP resin, which has high moisture barrier characteristics, for either the inner or outer layer, moisture barrier can be enhanced in cosmetic containers where the content is particularly susceptible to moisture loss ‐ such as mascaras or moisturizing lotions. (Image 6 – far right)
  • Glass‐like thick base container The process can be used to fully simulate visually stunning, glass‐like containers for premium quality cosmetics. (Image 6 & Image 7) The complex eye‐catching colors and extra thick wall and base are available either in bottles or jars.
  • Unique design container – Integrated stripes, internal ribs, gradation etc. Additional decorative features such as integrated stripes, internal ribs or gradation etc. can be added to the container design for maximum marketing impact.

www.nisseiasb.co.jp

Nissei ASB News

“Zero Cooling” Provides a Revolutionary Increase in Quality, Productivity & Efficiency at K2019

Nissei ASB Machine Co., Ltd. (Head office: Komoro‐shi, Nagano‐ken, Japan ‐ President: Junichi Miyasaka), a world leading manufacture of machines and molds for injection stretch blow molding of PET and other plastics, will exhibit at the K2019 exhibition (Hall 14 / B38), to be held in Düsseldorf, Germany from 16th to 23rd October 2019.

The “K” exhibition retains its place as the world’s largest and most influential plastics exhibition, with the 2016 event seeing over 230,000 visitors with over 82% directly involved in purchasing decisions, Nissei ASB’s 712m2 booth will be making a strong impact with the target audience with live molding demonstrations of five ASB‐Series machines strongly showcasing ASB’s recently introduced “Zero Cooling” molding process.

Zero Cooling trademark from ASB

Zero Cooling ‐ Patented Molding Technology

The major sectors of the PET container market that utilize one‐step injection stretch blow molding process are cosmetics, personal care, pharmaceutical, household and general food packaging, etc. where containers are more commonly designed for market appeal and brand quality, resulting in preform design that up to now has been a compromise between container quality and molding efficiency.

First announced in 2018, Zero Cooling ‐ ASB’s revolutionary advance in preform cooling technology ‐ perfectly suits the needs of these industries as it enables increased product quality at significantly shorter molding cycles than seen previously.

Taking full advantage of ASB’s proprietary 4‐station, 1‐step molding method, virtually all the required preform cooling is now shifted away from the injection station and into the second, conditioning station to dramatically reduce injection cycle times.

Crucially, the Zero Cooling molding method enables these short cycle times to be achieved while avoiding the need for thin, compromised design preforms that are susceptible to several quality related problems, most notably the undesirable “fisheye”, “body ring” and “orange peel”.

Now, with the preform designer able to freely focus on a shorter preform design with a thicker wall section that optimizes stretch ratios, the result is vastly improved quality as well as increased productivity.

Actual results from typical Zero Cooling molds have shown 15% or greater increase in stiffness and topload strength, improved control of material distribution and an average of 1.5 times productivity increases while improving on visual quality. Furthermore, since the container strength has now been improved by better orientation, more scope is available to apply additional light‐weighting to the container’s specification.

The advanced cooling method also enables the molding of heavyweight premium cosmetic containers in dramatically shortened cycle times exhibiting no haziness even when using standard, lower cost PET grades, rather than the higher priced specialized, low‐crystallization grades that are normally required. All this results in perfect visual quality while saving cost and boosting productivity by 2‐3 times over conventional molding of these glass‐like, premium designs.

Zero Cooling Trademark Molding Technology from ASB

Protecting Nature

The advantages of Zero Cooling not only benefits users of ASB equipment but also demonstrate ASB’s commitment to provide high quality molded products that help protect the natural environment.

  • Increased productivity provided by Zero Cooling equipped molding systems
    reduces the overall energy consumption per bottle.
  • Additional container strength provided by Zero Cooling allows further
    opportunities for weight reductions
  • Two of the five machines on demonstration will be molding 100% R‐PET that fully
    confirms the ability of Zero Cooling to produce highest quality containers at high
    efficiency over a range of material specifications.

 

1. ASB-12M v2 1 -Step Injection Stretch Blow Molding Machine with Optional Take-Out Unit – Small Size with Vast Capability

The ASB‐12M has firmly established itself as a leader in the class of small, fully automated 1‐step stretch blow molding machines with its diminutive size belying its huge capabilities. Now in its Version 2 specification, the model brings even greater performance and utility to the table.

ASB-12M v2 1 -Step Injection Stretch Blow Molding Machine with Optional Take-Out Unit

Most notable is the Vision1 control system that elevates the machine capabilities to a whole new level offering significant advantages to users;

  • Response & communication speed is 2.5 times faster than dedicated PLC systems enhancing machine cycle efficiency and control precision.
  • PC based system makes it extremely flexible in use and compatible with Industry 4.0 for enhanced factory networking.
  • Larger, easy to read panel provides easier access to relevant information without changing pages.
  • Most manual operation switches are replaced by touchscreen operation. Improved operator feedback improves troubleshooting response time and minimizes down‐time. Internal hard wiring is drastically reduced.
  • Major machine functions can be added or updated via software installation only.
  • Easier & faster service support.
  • Standardized interface across the model range assists in operator training.

 

The revised ASB‐12M expands the capabilities for production of a vast range of PET containers, including highly efficient light‐weight bottles and wide mouthed jars, to the highest quality at low capital investment.

Key features include;

  • Ability to process more than 20 resin types in addition to PET.
  • Molds containers from 5ml or less all the way up to 2.5‐liters capacity.
  • Variable cavitation for up to 15mm neck diameter bottles in eight cavities through to 83mm neck diameter jars in a single cavity.
  • Servo driven hydraulic pumps installed as standard, contributing to major energy savings and offering smooth and extremely quiet operation.
  • Backwardly compatible with existing class mold tooling with minimal modifications.
  • Small size allows fast mold changeovers will minimal manpower, and minimal lifting equipment.

 

In addition, the model displayed at K2019 will be fitted with the optional IU‐10L long stroke injection unit that provides a 50% increase in available shot‐size, expanding the scope for large containers, heavy‐weight cosmetic bottles, or materials such as polypropylene having lower density.

All these benefits make it an ideal platform for a start‐up company looking to make future‐proof investments into an ever‐changing market, or for larger companies wishing to exploit niche markets where higher margins are to be found. With its full featured specification, it also makes an ideal laboratory machine for R&D work and pilot molding before committing to much larger multi‐cavity systems for major projects.

At K2019 this machine will be molding a 4‐cavity “family” mold featuring two separate premium grade, glass‐like cosmetic container designs of 80ml and 45ml fill capacity sharing a common preform design. Thanks to the use of Zero Cooling, the cycle has been reduced from a typical previous time of up to 40 seconds down to just 12.5 seconds to achieve greater than 3 times increase in productivity. Additionally, this revised cycle is being achieved using standard bottle grade PET – specialized, high‐priced slow crystallizing PET resin resins are completely unnecessary when Zero Cooling molding is employed.

2. ASB-12M v2 1 -Step Injection Stretch Blow Molding Machine with Optional Take-Out Unit – Ultimate Versatility

This mid‐range ASB‐70DPH model has been a favorite for over 30 years due to its economy, flexibility and convenient size – and due to regular technology updates, it has stayed at the forefront of 1‐step molding technology with class leading efficiency. With the ability to mold PET and up to 20 other resin types, combined with the capacity to mold up to 10‐liter capacity jars in a single cavity all the way through to sub‐100ml bottles in up to 12 cavities, it is little surprise that this model takes the “best‐seller” award on so many occasions.

ASB-12M v2 1 -Step Injection Stretch Blow Molding Machine with Optional Take-Out Unit

The ASB‐70DPHv4 is a mid‐range one‐step injection stretch blow molding machine that offers extreme molding versatility in a “just‐right” size with competitive investment costs and low cost of ownership. It utilizes ASB’s renown 4‐station molding process to achieve optimum molding efficiency and stability of a wide range of molding materials.

It has remained a long‐term industry’s best seller in its class for a variety of reasons;

  • Ability to process up to 20 resin types in addition to PET.
  • Molds containers from 50ml or less all the way up to 10 liters’ capacity.
  • Variable cavitation from 18mm neck diameter small bottles in 12 cavities through to 149mm neck diameter jars in a single cavity.
  • With almost 2,500 units shipped, the design is well proven as solid and ultra reliable.
  • A wide array of factory options allows buyers to tailor the machine to their own project‐specific needs.
  • With no hydraulic components above the molding area the risk of product contamination is eliminated.

 

At the K2019 exhibition, this version 4 model will be demonstrated molding a 250ml cylindrical shampoo / cosmetic container at a cycle of 13.4 secs with 10 cavities producing over 2,600bph.

The demonstrated container design falls into a category that is often difficult to mold with perfect visual quality. Its small neck to body diameter ratio and a higher‐thannormal weight as per the client’s requirement for a “quality feel” would cause molding compromises with a standard mold. However, with the added benefits that Zero Cooling provides, not only is the productivity increased over a standard mold, the visual quality of the container becomes flawless.

3. ASB‐70DPH – Advanced Version

Although its external appearance is extremely similar to the standard version on display, the ASB‐70DPH Advanced Version has been fully re‐engineered to demonstrate a variety of techniques to achieve dramatically reduced indexing time that fully complements the Zero Cooling process and provides dramatically enhanced output, especially for smaller containers.

Key points being demonstrated on this concept machine include;

  • Revised hydraulic circuit provides faster, smoother motion of clamping.
  • Adjustable stroke in all clamping stations reduces machine indexing time for shorter preforms, while adjustable daylight also allows longer preforms, a feature especially useful for many non‐PET molding resins.
  • Fully revised blow station reduces index time, simplifies blow mold changeover and reduces maintenance.
  • Compatibility for existing ASB‐70DPH molds is maintained.
  • Height adjustment system for injection unit reduces mold changeover times in high product mix molding scenarios.

With this Advanced Version machine giving a 40% reduction in indexing time, the demonstrated container using a short preform can be molded at up to 2.4 seconds faster than that achievable by a standard model. This saving is in addition to the reduced cycle time obtained from the use of Zero Cooling technology in the mold design. Combining the aforementioned machine revisions with ASB’s Zero Cooling mold technology, the 8‐cavity, single row mold producing a 30ml, 3.8gram, 19mm screw neck container for medical or toiletry use will cycle at 4.4 seconds to provide over 6,500bph.

4. ASB‐70DPW v4 ‐ High Output of Small Containers in Various Resins

The double‐row molding equivalent to the ASB‐70DPH is optimized for production of smaller bottles in molding configurations from 8 to 24 cavities for high productivity of containers up to 1‐liter capacity, and as with all ASB Series machines, the ASB‐70DPW is perfectly capable of molding a variety of non‐PET resins.

Assisting with energy saving, the servo hydraulic system provides power consumption savings of 30‐40% compared to the same mold and cycle time running in a conventional machine, while an optional blow air recycle system has the capability to take exhausted blowing air back into the machine system for air cylinder operation thus saving energy at the operation (low pressure) air compressor.

Now fitted as standard, an enhanced mold changing system in all stations permits drastic reductions in overall mold change time. For a blow mold change, just 30% of the previous time is required while for a total and complete preform and blow mold change, around 50% of the previous time is required.

At K2019, the machine will be molding an oval 300ml shampoo container in 14 cavities at a cycle time of 13.6 secs to generate over 3,700bph using a 100% recycled R‐PET.

5. ASB-70DPW v4 1-Step Injection Stretch Blow Molding Machine – High Scale Productivity of Bottles & Jars

The largest model on display is part of the ASB‐150 Series that operate using single, double or triple row molding. Despite being a high productivity machine for small to medium sized containers, the double row layout of the ASB‐150DPW also has the versatility to mold a wide variety of bottles and jars in PET and other resins, such as PP infusion bottles, to satisfy a wide range of users’ needs. Output is typically around 2.5 times that of the smaller ASB‐70DPW.

ASB-70DPW v4 1-Step Injection Stretch Blow Molding Machine

With its design based on the shared ASB‐150DP / ASB‐150DPX mechanical architecture, operation, maintenance and spare parts share many common features, thereby reducing total cost of ownership where its siblings are also in use. Energy consumption is maintained very low due to the adoption of standard variable displacement or optional servo driven hydraulic pumps.

The ASB‐150DPW is capable to mold containers from 1.5‐liter jars with 94mm necks to sub‐150ml bottles ranging from 8 to 36 cavities.

ASB-150DPW 1-Step Injection Stretch Blow Molding Machine

Perfect visual quality matched with improved physical quality at higher productivity rates – Zero Cooling molding demonstrations at K2019

At K2019, the machine will be demonstrated molding a 900ml, 70mm neck diameter general food jar in 14 cavities. The adoption of Zero Cooling offering a cycle of 9.4 seconds means that productivity will exceed 5,300bph while molding outstandingly strong containers in 100% R‐PET

Additional Information

Each machine will be displayed with a full line of matched molding ancillary equipment that the company is able to supply, such as resin dryer, chiller, mold dehumidifier and mold temperature controllers, take‐out units etc.

ASB’s booth will also be exhibiting an exciting range of developments and packaging technologies including two‐layer bottles, canted/tilted neck bottles, polycarbonate 5 gallon with blown handle, double wall cup, HDPE bottles by ISBM, thick wall / base cosmetic bottles, etc.

 






Nissei ASB Machine Co Ltd, Introducing the PF36 Family

 

Building on the success of the PF24-8B 1.5 Step Injection Stretch Blow Molding machine first launched at K2013 in Düsseldorf, Nissei ASB recently debuted the first of its new PF36 Series at China Brew & Beverage 2018 in Shanghai. The new model line-up extends the range and capabilities of the platform providing higher productivity and even greater efficiency

 

1 Step Injection Moulding Machine

The 1.5-Step Molding Process

Traditionally, PET bottles are made either by the 1-step or 2-step molding processes. In the 1-step process, containers are molded directly from PET resin in a single injection stretch blow molding machine where the residual heat from injection is used to allow blowing of the bottle. In the 2-step process, raw material is first injection molded into preforms which are then stored or transported at room temperature before being re-heated and blown into the finished container by a separate stretch blow molding machine. Depending on the container type and local market conditions, each process has its own merits.

As the world’s leading one-step machine manufacturer, ASB recognized the merits of each system and, in 1995, combined them into a pioneering molding system that became known as 1.5-step molding. In this process, preforms are injected in a greater number of cavities, partially cooled to maximize stability then temperature conditioned before being passed to a blow mold containing 1/3 the number of cavities of the preform mold.

Step Molding Process

Since it normally takes around three times longer to injection mold a preform than to blow a bottle, this means that each part of the machine operates at maximum utilization and investment costs for blow molds are reduced.

In this latest iteration of the successful family of PF Series of machines, preforms are injection molded in batches of up to 36 then partially cooled to provide a stable starting point for the rest of the process. Preform temperature is then raised and optimized in a continuous flow heating oven before being passed to the blowing station for re-heat stretch blow molding.

1 Step Injection Blow Moulding Machine

The result is an extremely compact bottle molding machine that operates at high efficiency and produces the highest quality of finished bottle because, as in the one-step system, preforms are never released,eliminating risk of scuffing or neck deformation. To achieve the same output by two-step molding at least 2-3 times the factory floor area would be required, product handling costs are increased, and the container visual and neck quality would be significantly lowered.Additionally, by blowing the bottle within the same machine that molds the preform, risk of contamination is eliminated, and the hygiene of the bottle is assured, making the machine ideally suited to an in-line filling operation for beverage products. The model shown at ChinaBrew was the PF36/36-600 denoting that it molds 36 preforms per cycle and is capable to mold bottles up to 600ml capacity. Blow molding is carried out by an integrated 12 cavity linear blow system that operates three times per injection molding cycle.

 

Mold Cavity

Other models built on the same platform include;
 

  • PF36/24-1500 – 24 preforms and 8 blow cavities up to 1,500ml.
  • PF36/18-2000 – 18 preforms and 6 blow cavities up to 2,000ml.
  • PF36/12-5000 – 12 preforms and 4 blow cavities up to 5,000ml.

 

There are also systems currently under development at ASB that will use the same molding principle for PET bottles up to 20 liters capacity.

Compared to the previous PF24 model, the new PF36/36-600 has a footprint that is just 30cm longer but increases productivity by around 50~80% from around 9,000bph up to 14,000~17,000bph dependingon the container specification. Part of that increase comes from increased cavitation, but dry cycle time has also been significantly reduced in the blow station, while further developments in preform cooling have seen reductions of up to 30% in injection cycles over previous models.

At CBB2018 the machine was demonstrated molding a 500ml, 8-gram water bottle at 14,500bph. This weight represents the lightest practical weight in this class of container and highlights the continual efforts by ASB to reduce the impact of plastics on the environment as well as providing its customers with the most cost-effective molding solutions.

 

Efficient Hybrid Functions

The injection unit and injection mold clamping are hydraulically operated, utilizing low energy consumption variable displacement pumps, but downstream from there all major movements are driven by servo motors including the blow mold clamp and stretching, while pneumatic operation is reserved for the small and simple motions.

The resultis a remarkably low actual energy consumption of just 66kW to mold a 500ml bottle at an output more than 14,500bph which makes it highly economical considering that this is total power requirement for full conversion from raw material to finished product. Further energy savings are achievable at the air compressors with an optional blow air recovery system.

With the linear blow molding system operating at three times per injection cycle, for small light weight bottles where theoretical output may exceed 17,000bph the linear blow system may need to operate at sub 2.5 second cycle times. In combination with the servo driven systems, ASB’s recently introduced Vision1 machine control system provides high speed, smooth and synchronized control of multiple movements that enables these cycle times to be easily achieved while ensuring incredibly low noise and vibration.

 

Advanced Injection

Where light weight preforms are being molded in short cycle time, the screw charging recovery can be a limiting factor on minimizing cycle time, so as a countermeasure, a holding pressure cylinder is mounted on the front of the injection barrel that maintains pressure within the cavity, allowing screw recovery to occur simultaneously thus ensuring the shortest possible cycle time is achieved.

Mold Cavity

In the case of high shot weights combined with short cycle times a more advanced injection unit using a two-stage (shooting pot) design may be utilized. Both of these systems provide gentle plasticization of the material at high throughputs to ensure molded products are of the highest possible quality.

 

Vison1 Control System The model line-up features ASB’s new advanced control system, dubbed Vision1. This industrial PC based system provides a long list of advantages for potential users of the PF36 Series, one of the key points being improved system integrationover dedicated PLC systems which enhances machine cycle efficiency and control precision – vitally important in the high-speed movements in the blow station. This PC based system is extremely flexible in use and is compatible with the Industry 4.0 standard for enhanced factory networking into the IIoT (Industrial Internet of Things). A larger, 18.5 inch easy to read panel provides the operator with easier access to relevant information without changing pages. Flexibility of operation and cost of manufacture and maintenance have been reduced by transferring most manual operation switches to touchscreen operation and within the machine, hard wiring is drastically reduced. Overall, the system provides the operator with improved feedback to reduce troubleshooting response time and minimize down-time. Easier & faster service support is available and where future developments are made, machine functions can be added or updated via software installation only.

 

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ASB Demonstrates Wide  Ranging Technologies for Improved Productivity & Next Generation Manufaturing at NPE 2018

 

Nissei ASB Machine Co., Ltd. (Head office: Komoro-shi, Nagano-ken, Japan - President: JunichiMiyasaka), a world leading manufacture of machines for injection stretch blow molding of PET and other plastics, will exhibit at the NPE 2018 exhibition (Booth S19045), to be held in Orlando, USA from 7th to 11thMay 2018.  Live molding will be demonstrated featuring five machine models together with a display of some of the most interesting recent updates in injection stretch-blow molded packaging technology.

 

NPE 2018

In 2015 the NPE exhibition set new records by attracting 2,029 exhibitors from 37 countries in a floor area of more than 104,000sq.m.  More than 65,000 registered visitors attended, showing a 19% growth over the previous exhibition.  Most importantly, the quality of the visitors is traditionally very high with the majority representing their respective companies as senior management with strong decision-making power. In 2015, 44% of exhibitors and 26% of visitors were from overseas.

As the largest plastics exhibition in the Americas, and the US economy showing strong growth, NPE 2018 is expected to exceed the records set in 2015 making it one of the most important marketing events for Nissei ASB to attend.

Reflecting consistent sales growth over the last 3 years, ASB will represented by its largest ever presence at NPE with a 740-square meter booth and five different machine models making live molding demonstrations molding a variety of products that showcase the versatility of the company’s technology and integration with the Internet of Things.

Featured models will include;

 

  1. ASB-12Mv2 – Entry level & niche market four station one step injection stretch blow molding machine featuring next-generation control system and radically shortened cycle time for heavyweight cosmetic containersusing standard PET resin.
  2. ASB-70DPHv4 – Superbly versatile mid-range four station one-step injection stretch blow molding machine demonstrating visually perfect molding of Tritan Co-polyester resin.
  3. ASB-150DPX – World’s first triple row, one-step injection stretch blow molding machine molding in 48 cavities and over 20,000 bottles per hour
  4. HSB-2M/6 – 2-step re-heat stretch blow molding machine featuring ASB’s double-blow heat-set technology for heat resistant large necked jars.
  5. HSB-6N – 2-step re-heat stretch blow molding machine featuring ASB’s double-blow heat-set technology for heat resistant beer bottles complying with the industry standard tunnel pasteurizing process.

 

The booth will also be exhibiting a full line of matched molding ancillary equipment that ASB is able to supply, such asresin dryers, chillers, mold dehumidifiers and mold temperature controllers.  In-house custom designed pick and place take-out units with conveyor systems will also be demonstrated allowing prospective customers to easily install the molding machines up-stream of otherprocessing equipment or a filling line.

All models will be operating on a daily molding schedule and the booth will include a wide range of samples and displays of other specialized technologies from ASB.

Detailed descriptions of each of the featured models can be found on the following pages. Additional high-resolution images are also available separately.

 

ASB-12M v2 – Fast Cycle Cosmetic Molding & Next-Generation Advanced Control System

The ASB-12M, first launched in 2012, has been hugely successful as an entry level and niche market model that provides a scalable and highly versatile manufacturing solution withextremely low energy consumption.Now in 2018, ASB is launching a revised edition that maintains the solid mechanical design and energy conserving servo-hydraulic system,and adds an all new control system operating to the Industrie 4.0 computerized manufacturing standard allowing factory integration via the so called, “Internet of Things”.

 

The v2 machine will be demonstrated molding a 4 cavity, 40ml premium quality thick walled cosmetic container in a family type mold of two differing designs.  With a weight of over 31 grams, the resulting PETwall thickness of 2mm perfectly simulates the high-grade appeal of glass– but most notable is the cycle time improvement for this class of heavyweight container from a typical requirement of 40+ seconds down to an outstanding 13.4 seconds resulting in a three-times increase in productivity.

 

Normally, molding a container of this thickness at this incredible cycle time would require the use of specialized or expensive resins to avoid haziness from crystallization.  But,designers at ASB have taken full advantage of the preform conditioning station, that only exists in ASB’s four station molding machines, to create a(patent pending) system that modifies the preform’s temperature profile, shape and thickness prior to its transfer to the blow station.In this process, the molding of containers at this cycle time is perfectly stable with excellent clarity using standard PET resin making it suitable for use in real-world manufacturing situations.

 

While the majority of cycle improvement comes from the intensive use of the conditioning system in the second station, the dry cycle time and operational movement of the machine has also been improved by the addition of a next-generation computerized control and interface system that offers significant advantages to users;

  • Faster response & communication speed than dedicated PLC systems enhances machine cycle efficiency and control precision.
  • PC based system makes it extremely flexible in use and compatible with Industrie 4.0 for enhanced factory networking.
  • Larger, easy to read panel provides easier access to relevant information without changing pages.
  • Most manual operation switches are replaced by touchscreen operation.
  • Improved operator feedback improves troubleshooting response time and minimizes down-time.
  • Internal hard wiring is drastically reduced.
  • Major machine functions can be added or updated via software installation only.
  • Easier & faster service support.
  • Standardized interface planned across the model range assists in operator training.

 

Despite the small size of the machine, it has a vast range of capabilities for production of all types of PET containers including highly efficient light-weight bottles, and medium sized jars.  The ASB-12M’s popularity is further enhanced by its ability to process a wide range of non-PET resins combined with very low total cost of ownership.

 

Key features include;

  • Ability to process more than 15 resin types in addition to PET.
  • Molds containers from 5ml or less all the way up to 2,500ml capacity.
  • Variable cavitation from 15mm neck diameter eye drop bottles in eight cavities through to 83mm neck diameter jars in a single cavity.
  • Servo driven hydraulic pumps installed as standard, contributing to major energy savings and offering smooth and quiet operation.
  • Backwardly compatible with existing class mold tooling with minimal modifications.
  • Small size allows fast mold changeovers will minimal manpower, and minimal / no special lifting equipment.

 

In addition, the model displayed at NPE will be fitted with the optional long stroke injection unit that provides a 50% increase in available shot-size, expanding the scope for large containers, heavy-weight cosmetic bottles, or materials such as polypropylene that have lower density.

These benefits make it an ideal platform for a start-up company looking to make future-proof investments into an ever-changing market.

 

ASB-12Mv2 Images

ASB-12M v2 with New Generation Control Interface

New Generation Controller Interface Screenshot

Family Type Cosmetic Mold

Perfect Clarity, Fast Cycle, Standard PET Resin

 

ASB70DPHv4 – High Versatility Model Maintains Its Position as Best Seller 

The ASB-70DPH is a medium sized, four station one-step injection stretch blow molding machine which can produce containers from PET and a wide range of other resins.

It has a long production record, with its extreme molding versatility and continually updated specifications it continues as one of ASB’s best-selling models, with current sales of over 2,100 units.

Already supremely versatile in its standard form, the ASB-70DPH is also available with a wide range of options that allow global users to further adapt its capabilities to cater to their local market needs.

 

Key to the success of this model are its many standard features;

  • From raw material to finished product in one compact machine,
  • Ability to process more than 15 resin types in addition to PET.
  • Molds containers from 50ml or less all the way up to 10 liters’ capacity.
  • Variable cavitation from 18mm neck diameter small bottles in 12 cavities through to 149mm neck diameter jars in a single cavity.
  • The ASB four-station molding process with preform conditioning at the second station that radically increases flexibility and molding stability can also provide increased production stability production over competitors’ three-station systems.
  • No hydraulic components above the molding area eliminates the risk of product contamination,

 

At NPE, the ASB-70DPHv4 will be utilizing a set of options that further increases its already formidable versatility;

  • Servo-Driven Hydraulic System - offers extremely low power consumption.  In tests using the same molds, an energy consumption reduction of 40% was achieved compared with the standard pump equipped model, and approx. 64% reduction compared with the previousgeneration ASB-70DPH v3.
  • Increased Injection Unit Capacity –ideal for larger containers, heavy-weight cosmetic containers or non-PET resin with lower densities, the optional IU-50 injection unit provides a 78% increase in shot size.
  • ExtendedDaylight for Injection Clamp – a factory option of extended injection clamp daylight provides even greater flexibility in molding of longer preforms as is often required when molding non-PET resins where optimum stretch ratios are different from those of typical PET containers.

 

The machine will be demonstrated molding a 700ml Copolyester (Tritan) 90 gramsre-usable drinking flask in a four-cavity family mold at a cycle of 14.4 seconds.The design of the container has been carefully selected to show off the superb visual quality that is only achievable with the one-step molding process.

 

ASB-70DPHv4 Images

ASB-70DPH v4 with Optional NVES-70 Take Out Unit

Sports Drink Bottle in Tritan Copolyester

One-Step Injection Stretch Blow Molding

Extended Daylight Increases Versatility

 

 ASB-150DPX– World’s First Triple Row, One Step Injection Stretch Blow Molding Machine 

 

Making its debut on the American continent at NPE 2018, Nissei ASB’s triple row, high output ASB-150DPXmodel for small bottle production will demonstrate the latest in a long line of world firsts that the company has achieved throughout nearly 40 years at the forefront of the PET container industry.

 

The recently developed ASB-150DPX expands the company’s flagship ASB-150 based models to three variants;

  • ASB-150DP – Single row molding up to 16 cavities, for very large bottles and jars.
  • ASB-150DPW – Double row molding of medium sized bottles and jars up to 32 cavities.
  • ASB-150DPX – Triple row molding of small bottles in 24, 36 or 48 cavities.

 

All models are built on a common architecture so factory layout, key functions, spare parts, maintenance and operator training are common to all, thereby reducing total cost of ownership for users of more than one model type.

 

In addition, the newly added DPX model has specific design features to maximize efficiency in small container molding with several areas of the machine design having patents pending or already approved;

  1. Injection clamping stroke is optimized to minimize dry cycle time for short cycle small containers.
  2. Upgraded hydraulic components provide faster cycle of injection clamping while maintaining smooth machine movement.
  3. Servo hydraulic pumps as standard offer up to 30% reduction in energy consumption.
  4. Blow air circuit is optimized for small container production offering up to 50% reduced air consumption over standard systems.

 

Although these features were specifically developed for the ASB-150DPX, many of them are also planned for future updates of its stable-mates ensuring that the entire model range maintains its lead over the competition.

At NPE, the ASB-150DPX will be conducting daily molding demonstrations of a 50ml, 10.5-gram liquor miniature bottle in an unprecedented 48 cavities mounted in a triple row molding layout.  With a cycle time of 8.6 seconds the machine will operate at a production rate in excess of 20,000 bph. 

 

This container design requires a very small preform that would be impossible to handle and re-heat in a two-step system so the one-step molding process, where the container is formed directly from resin within one machine and held securely by its neck throughout, is the only practical choice.  The smaller the container, the more advantageous it is for production using a large one-step machine with high output.Molding the container on a one-step system also provides superb visual quality and ensures that the neck remains free of any scuffing or damage that could compromise the neck seal.

Even if a container design such as this could be molded by re-heat blow molding, the required floor area for a similar capacity two-step production unit is typically 3-4 times greater, so this one-step solution provides not only technical superiority and enhanced quality, but manages to achieve it in a significantly reduced production space.

 

The machine has already generated strong interest in the dairy sector for products such as flavored milk and yoghurt based drinks where it will typically mold lightweight containers in 36 cavities.  In its 24-cavity configuration the machine is capable of molding round or oval containers up to 300ml with a 38mm neck which also makes it ideal for single serving juice or water bottles.

 

ASB-150DPX Images

ASB-150DPX Overview

Liquor Bottle at 20,000 per Hour

Triple Row Blow Cavity

Cavities at Container Eject Station

HSB-2M/6 – Increased Molding Capacity for Heat Resistant Jars up to 1 Liter

 

The HSB-2M/6 is a 2-step, re-heat stretch blow molding machine featuring ASB’s unique double-blow heat-setting process and expands the range of models in the HSB series, with the capability to mold 6 cavities of 1-liter jars with thread diameter up to 86mm.

 

These models have been developed specifically for the production of wide mouthed hot- fillable&pasteurizable jars, ideal for many foodstuffs including pickles, jams, marmalade and a wide range of sauces. They utilize the same tried and trusted double-blow technique used in the HSB bottle production machines, so high container performance is assured.

 

Preforms can either be molded in-house using one of ASB’s PM Series preform injection molding machines, then processed by a CM Series neck crystallizer, or for those users wishing to minimize capital investment, customized preforms can be supplied direct from ASB to anywhere in the world.

 

To optimize the process efficiency, molding can be adjusted to apply almost any degree of heat resistance to a PET container as required by the filled product.  However, as the 2-step double-blow heat-set process of the HSB-2M/6 can achieve heat resistance all the way up to the practical maximum of PET – approx. 95°C with a suitable container design and cap – it is extremely effective for those projects that exceed the capability of other heat-setting processes.

 

With fully electric mold clamping, the machine is smooth, quiet and energy efficient and for added flexibility, with a simple change of blow mold and a suitable preform it is equally capable of molding standard (non-heat resistant) PET containers.

 

At NPE, the HSB-2M/6 will be molding a 500ml jar with an 80mm neck suitable for a metal, twist-off lug type closure designed for filling at 88°C.  With a 6-cavity configuration, the 4.5 second cycle offers an output of 4,800 bph.  The container features a panel-free design where the body is plain round for easy labelling and internal vacuum forces generated by cooling products are absorbed by a patented base design that flexes during filling, heating and cooling to ensure no distortion in the labelled area.

 

Use of the industry standard metal lug-type cap is essential to provide current filling companies with an easy change-over route to PET, but it exerts uneven force on the neck that could cause problems with distortion or leakage. However, with the use of a crystallized neck and ASB’s advanced molding techniques the jar passes all tests with ease.

 

The demonstrated jar has been specified to satisfy a practical filling requirement for cheese sauce;

  • Filling at 88°C to reduce product viscosity, which also initiates pasteurization in the product,
  • Tunnel showering to maintain the core temperature at a minimum of 72°C for 10 minutes to complete pasteurization,
  • Controlled cooling to below 30°C over a period of 35 minutes.

 

This filling process is typical for sauces such as cheese dip that have a high viscosity, the elevated temperature allows faster filling with no voids in the contents.  Higher viscosity products such as these place a higher heat load on the container during the cooling phase as convection currents cannot form to aid cooling, however the advanced and stable heat resistance achieved by the HSB double-blow molding technique assures satisfactory container performance.

 

HSB-2M/6 Images

HSB-2M/6 Overview

Panel-Free Heat Resistant Jar & Preform

Jar Preforms Just Prior to Inversion & 1st Blow

Completed Jars Leave the 2nd Blow Mold

 

HSB-6N – Leading Performance for Heat Resistant Bottle Molding

 

 

The HSB-6N machine performs double-blow re-heat stretch blow molding in a compact solution for heat resistant PET bottles with neck diameter up to 38mm. Preforms with either amorphous or crystallized neck may be molded with equal ease, the choice of neck type depends on factors such as neck and cap design, container filling, pasteurization and cooling specifications.

 

To optimize the process efficiency, molding can be adjusted to apply almost any degree of heat resistance to a PET container as required by the filled product.  However, as the 2-step double-blow heat-set process of the HSB-6N can achieve heat resistance all the way up to the practical maximum of PET – approx. 95°C with a suitable container design – it is extremely effective for those projects that exceed the capability of other heat-setting processes.

With fully electric mold clamping, the machine is smooth, quiet and energy efficient and for added flexibility, with a simple change of blow mold and a suitable preform it is equally capable of molding standard (non-heat resistant) PET containers.

 

At NPE, the machine will be demonstrated molding a heat resistantPET beer bottle that meets the standard industry requirements of 65°C contents temperature, to be maintained for 15 minutes to fully kill off any remaining yeast and provide long stable shelf life with no apparent flavor change.  Despite this relatively low temperature of pasteurization, a combination of long processing time and carbonation pressurecreates additional forces on the container that can only be adequately handled by the double-blow heat-setting process in combination with the 36.5 grams weight.  It can be molded in standard PET, or where required, oxygen scavenging or carbon dioxide retention additives can be included to further enhance the shelf life.

 

The demonstrated 650ml bottle will be molding at a cycle of 4.5 seconds producing 4,800bph and thefeatured container uses an industry standard neck suitable for crown caps, but could be molded to any required standard.

 

The container specification adheres to the standard industry bottling process for pasteurized beer;

  • Filling at 5°C and capping,
  • Hot shower until core temperature is 65°C (approx. 35 mins)
  • Maintain 65 °C for a period of 15 minutes.
  • Cold shower back to room temperature.

 

The HSB-6N offers an ideal solution to converters and fillers of all types of bottled beverages that require a versatile, small to medium output machine that provides the highest heat resistance PET containers currently available in the industry.

 

HSB-6N Overview

PET Beer Bottles with Standard Caps

Re-Heated Preforms Just Prior to 1st Blow Molding

Bottles Are Ejected After 2nd Blow Molding

Range of PET bottles






Nissei ASB Machine at the IPF 2017 Exhibition

Nissei ASB Machine Co., Ltd. (Head office: Komoro-shi, Nagano-ken, Japan –Representative director: Daiichi Aoki), a world leading manufacturer of machines for one-step injection stretch blow molding of PET and other plastics, will exhibit at the IPF 2017 exhibition (Booth 72202), to be held at Makuhari Messe, Japan from 24th to 28th October 2017.  Live molding will be demonstrated on ASB’s 250 square meter booth with two machines together with a display of some of the most interesting recent updates in injection stretch-blow molded packaging technology.

 

ASB Machine

 

IPF 2017

Held every 3 years in Chiba-Prefecture Japan, the IPF exhibition is Japan’s premiere event for the plastics and rubber industry.  In 2014 the fair attracted 43,000 visitors with nearly 10% coming from 45 overseas countries. Over 770 exhibitors participated from a total of 27 countries with 81% reporting that the exhibition provided either good or very good sales promotion results. Forecasts for 2017 estimate that attendance of exhibitors and visitors is expected to rise by around 4-5% over 2014 levels.

ASB Theme

Two machines will be making live molding demonstrations. In direct contrast to the oft-seen “concept molding” approach of unrealistic weight and cycle times that cannot be reliably converted into actual production, ASB will be focusing on highly efficient, stable molding of premium quality products that are optimized for the real-life production environment.

 

ASB Machine

 

ASB-12Mv2 -High Speed Cosmetic Container Molding & Advanced Control System

Nissei ASB will be presenting an update of its hugely popularASB-12M model (prototype) for small container molding.  The revised version now making its global debut in corporates an all-new control and interface system that offers significant advantages to users;

  • Adapted larger, easy to read 15” touch panel provides easier access to relevant information without changing pages. (Previous panel was 12”.)
  • Simple operation by touch screen operation.
  • PC based system makes it extremely flexible in use and compatible with Industrie 4.0 for enhanced factory networking.

In the future, more convenient functions for users listed below will be supported.

  • Improved traceability & quality control.
  • Improved operator feedback improves troubleshooting response time and minimizes down-time.
  • Easier & faster maintenance available.

 

The new version maintains all of the capabilities for production of a vast range of PET containers, including highly efficient light-weight bottles and wide mouthed jars, to the highest quality while providing very low total cost of ownership. Key features include;

  • Ability to process more than 15 resin types in addition to PET.
  • Molds containers from 5ml or less all the way up to 2.5-liter capacity.
  • Variable cavitation from 15mm neck diameter eye drop bottles in eight cavities through to 83mm neck diameter jars in a single cavity.
  • Servo driven hydraulic pumps installed as standard, contributing to major energy savings and offering smooth and extremely quiet operation.
  • Backwardly compatible with existing class mold tooling with minimal modifications.
  • Small size allows fast mold changeovers will minimal manpower, and minimal or no special lifting equipment.

 

In addition, the model displayed at IPF will be fitted with the optional long stroke injection unit that provides a 50% increases in available shot-size, expanding the scope for large containers, heavy-weight cosmetic bottles, or materials such as polypropylene that have lower density.

All of these benefits make it an ideal platform for a start-up company looking to make future-proof investments into an ever changing market, or for larger companies wishing to exploit niche markets where higher margins are to be found. With its full featured specification, it also makes an ideal laboratory machine for R&D work and pilot molding before committing to much larger multi-cavity systems for major projects.

At IPF 2017 the machine will demonstrate molding of a 31 gram, 46ml premium quality cosmetic bottle featuring an average wall thickness of 2mm giving it a glass-like feel and appearance.  Despite the high weight, the advanced four cavity family mold will output over 1,000bph -  around 50% higher than similar quality production from competitors’ machines.

 

ASB Bottles
ASB Bottles

 

ASB-70DPHv4 – Best Selling Versatility in a Compact Package

The ASB-70DPH is a mid-range one-step injection stretch blow molding machine that offers extreme molding versatility in a “just-right” size with competitive investment costs and low cost of ownership.  It utilizes ASB’s renown 4-station molding process to achieve optimum molding efficiency and stability of a wide range of molding materials. It has remained a long-term industry’s best seller in its class for a variety of reasons;

  • The ASB four-station molding process with perform conditioning station that radically increases flexibility and provides increased production stability production over competitors’ systems.
  • Containers molded from raw material to finished product in one compact machine,
  • Ability to process more than 15 resin types in addition to PET.
  • Molds containers from 50ml or less all the way up to 10 liters’ capacity.
  • Variable cavitation from 18mm neck diameter small bottles in 12 cavities through to 149mm neck diameter jars in a single cavity.
  • With more than 2,000 units shipped, the design is well proven as solid and ultra-reliable.
  • A wide array of factory options allows buyers to tailor the machine to their own project-specific needs.
  • With no hydraulic components above the molding area the risk of product contamination is completely eliminated.

 

The machine specification will feature ASB’s optional servo-driven hydraulic system that achieves extremely low power consumption.  In tests using the same molds, an energy consumption reduction of 40% was achieved compared with the standard pump equipped model, and approx. 64% reduction compared with the previous generation ASB-70DPH v3.

The product to be molded is a six cavity 60 gram, 500ml shampoo container in a family mold featuring heavy engraving for a premium quality look and feel that is typical for the Japanese market.  The output of just over 1,000bph is again exceptional for a container of this weight and quality and perfectly demonstrates the advantages of one-step injection stretch blow molding for versatile molding requirements.

Interested visitors may also view a full line of matched ancillary equipment that ASB is able to supply for all its models, such as resin dryer, chiller, mold dehumidifier and mold temperature controllers.  Each machine will also be equipped with ASB designed pick and place take-out units with conveyor system allowing prospective customers to easily install the molding machine up-stream of a filling line.

VISIT NISSEI ASB Listing

Nissei ASB South Africa (Pty)Ltd


  Telephone     +27 12 345 4924

  Fax                 +27 11 345 5667

  Email               sales@nisseiasb.co.za






ASB to Demonstrate World’s First Triple Row

Nissei ASB Machine Co., Ltd. (Head office: Komoro-shi, Nagano-ken, Japan - President: Daiichi Aoki), a world leading manufacture of machines for injection stretch blow molding of PET and other plastics, will exhibit at the Drinktec 2017 exhibition (Hall A4.322), to be held in Munich, Germany from September 11th to 15th 2017. Live molding will be demonstrated on ASB’s 215 square meter booth together with a display of some of the most interesting recent updates in injection stretch-blow molded packaging technology.

  ASB-150DPX Overview

 ASB-150DPX Overview 

 

Drinktec 2017

Held every 4 years in Munich, Germany, Drinktec provides the role of world economic summit for the beverage and liquid-food industry. As such, in its role as world leader in one-step molding technology Nissei ASB takes great interest in not only monitoring but also in contributing to the industry trends on show at the exhibition. In 2013, the exhibition saw a 14% growth in attendance over the 2009 event with 66,880 visitors from 183 countries to view exhibits from 1,433 companies representing 76 countries.

 

ASB-150DPX triple row blow-mold system visible at left side

 

ASB-150DPX One Step Injection Stretch Blow Molding Machine

At Drinktec 2017, Nissei ASB will be debuting its ASB-150DPX model with daily live molding demonstration of a complete molding system.

The newly developed ASB-150DPX expands the company’s flagship ASB-150 based models to three variants;
 ASB-150DP – Single row molding up to 16 cavities, for very large bottles and jars
 ASB-150DPW – Double row molding of medium sized bottles and jars up to 32 cavities
 ASB-150DPX – Triple row molding of small bottles in 36 or 48 cavities

All models are built on a common architecture so factory layout, key functions, spare parts, maintenance and operator training are common to all, however the newly added DPX model has specific design features to maximize efficiency in small container molding;
1. Injection clamping stroke is optimized for short cycle small containers.
2. Upgraded hydraulic components provide faster cycle of injection clamping while maintaining smooth machine movement.
3. Servo hydraulic pumps offer up to 30% reduction in energy consumption.
4. Blow air circuit is optimized for small container production offering up to 50% reduced air consumption over standard systems.
Although these features were introduced for the ASB-150DPX, items 2, 3, and 4 are also planned to be available in future updates of its stable-mates ensuring that the entire model range maintains its lead over the competition.

 

ASB-150DPX triple row product eject station

 ASB-150DPX triple row product eject station.  



This introduction of triple row one-step injection stretch blow molding is another in a long line of global firsts that Nissei ASB has achieved throughout nearly 40 years at the forefront of the PET container industry, with several areas of the machine design having patents pending or already approved.

At Drinktec, the ASB-150DPX will be conducting daily molding demonstrations of a 100ml, 5.3-gram yoghurt drink container. This lightweight container design requires a very short preform that would be impossible to handle and re-heat in a two-step system so the one-step molding process, where the container is formed directly from resin within one machine and held securely by its neck throughout, is the only practical choice. The smaller the container is, generally the more advantageous it is for production using a large one-step machine with high outputs.


With its triple row molding layout allowing 36 blow cavities, and at a cycle time of 6.4 seconds the ASB-150DPX will achieve a production rate in excess of 20,000 bph. Even if a container design such as this could be molded by re-heat blow molding, the required floor area for a similar capacity two-step production unit is typically 3-4 times greater, so this one-step solution provides not only technical superiority and enhanced quality, but manages to achieve it in a significantly reduced production space.

With the recent rise in prices of PE/PS materials, demand for PET conversion of this type of small container is increasing with numerous specific inquiries from major food manufacturers so the company is confident of good demand for this new model.

The exhibit will also be demonstrating a full line of matched molding ancillary equipment that ASB is able to supply, such as resin dryer, chiller, mold dehumidifier and mold temperature controllers. An in-house custom designed pick and place take-out unit with conveyor system will also be demonstrated allowing prospective customers to easily install the molding machine up-stream of a filling line.

 

 Live molding of lightweight PET yoghurt drink containers at Drinktec 2017

Live molding of lightweight PET yoghurt drink containers at Drinktec 2017

 

NISSEI ASB MACHINE CO., LTD.

NISSEI ASB MACHINE CO., LTD. is a major stretch blow molding machine manufacturer for the production of plastic containers including PET bottles.

Head Office Address: 4586-3 Koo, Komoro-shi, Nagano-ken, Japan

Foundation: 8th November 1978

Employees: 1,679 staff (Consolidated: September 2016)

Capital: 3.8 billion Japanese yen

Sales: 25.5 billion Japanese yen (Consolidated accounting: September 2016)

 

VISIT NISSEI ASB Listing





ASB to Demonstrate Four High Performance Machines & Advanced Technologies at K2016

ASB to exhibit at K2016

Nissei ASB Machine Co., Ltd. (Head office: Komoro-shi, Nagano-ken, Japan - President: Kota Aoki), a world leading manufactureof PET and plastic bottle stretch blow molding machines, will exhibit at K2016 (Hall 14 Booth No. B38), to be held in Duesseldorf, Germanyfrom October19th to 26th 2016.


ASB will be demonstrating four of its top-line molding machines,

  • PF24-8B/12 1.5-step injection stretch blow molding machine,
  • ASB-70DPW v4 1-step injection stretch blow molding machine,
  • ASB-70DPH/DB1-step double-blow heat-set injection stretch blow molding machine,
  • ASB-12M/IBM Injection blow molding machine.

In addition, a range of ASB’s specialized molding technologies and unique sample containers will be on display.

K2016

Held every 3 years in Duesseldorf, Germany, the K fair has long been regarded as the world’s largest and most important international plastics exhibition. Spread over 171,245 square meters, K2013 saw 218,000 visitors from 108 countries pass through the doors to view exhibits from 3,220 companies. The importance of K for exhibitors can be easily understood by the fact that 66% of K2013 visitors came from top or middle management and 82% of visitors were directly involved in purchasing decisions with the result that 92% of exhibitors reported expectations of successful post exhibition business.

 

For K2016, ASB will conducting live molding demonstrations of the following exhibits throughout each day;

 

PF24-8B/12 Molding Deep Grip Pinch Type Handle

High Performance 1.5-Step Injection Stretch Blow Molding Machine ASB demonstrate machines at K2016

The PF24-8B/12 machine uses ASB’s unique and pioneering 1.5-step molding process to injection stretch blow mold PET bottlesdirectly from raw material in an extremely compact space.In order to achieve the same output by alternative molding methods at least 2-3 times the factory floor area would be required.
Additionally, by molding the preform within the same machine that the bottle is blown, the quality and hygiene of the preform and finished bottle is of the highest possible level making the machine ideally suited to an in-line filling operation for food products.

The PF24-8B/12 machine uses ASB’s unique and pioneering 1.5-step molding process to injection stretch blow mold PET bottlesdirectly from raw material in an extremely compact space.In order to achieve the same output by alternative molding methods at least 2-3 times the factory floor area would be required.
Additionally, by molding the preform within the same machine that the bottle is blown, the quality and hygiene of the preform and finished bottle is of the highest possible level making the machine ideally suited to an in-line filling operation for food products.

ASB Molding containers at K2016At K2016, the demonstrated PF24-8B/12 machine will be molding an ovalPET 3 liter container suitable for applications such as fabric conditioner or edible oilin a mold configuration of 12 preform cavities and 4 blow cavities.
The container features a deep pinch grip style handle that uses specially designed blow molds and advanced molding methods to fully form the handle by blow molding alone. No handle inserter or injection molded handle is required giving a container that is cheaper to produce, utilizes less molding energy, is easy and comfortable to hold in the hand, and is easier to recycle.

In addition, the machine will also be demonstrating a newlydesigned neck orientation systeminstalled between the preform heating and the blow molding process that provides dual functions of ensuring optimized material distribution of ovalized preforms and ensuring that

flip-top or asymmetric caps are oriented correctly for pouring.
For increased versatility, the PF24 models can be converted at the customer’s factory between 12 injection / 4 blow cavity molding for bottles up to 5 liters; and 24 injection / 8 blow cavity molding for bottles up to 1.5 liters. By changing cavity configuration and molds, the same PF24 model seen at the K2016 exhibition is equally at home molding lightweight water bottles at up to 9,000bph.

 

ASB-70DPH/DB Double-Blow Heat-Set Molding in One Step

Mid-Range One StepInjection Stretch Blow Molding Machine with Heat-Set Capability ASB Double-Blow Heat-Set Molding in One Step

Due to its continual developmentand extreme molding versatility for a wide range of container designs and resins, the medium sized ASB-70DPrangeof one-step injection stretch blow molding machines have remained as one of ASB’s best-selling products since their introductionresulting in the sale of more than 1,800 units.
Nissei ASB is also a world leader in technologies for molding heat resistant PET containers for a wide range of hot filling and pasteurizable food applications using its specialized HSB Series range of machines that apply the double-blow heat-set molding technique for very high heat resistance.

Taking the above advantages into consideration, ASB has now developed the all new ASB-70DPH/DB for global debut at K2016that combines the versatility of the ASB-70DPH with the double-blow technique of the HSB series into a compact and versatile one-step injection stretch blow molding platform. It is expected to be a major opportunity for those smaller molding companies wishing to move into niche area hot filling, without incurring the investment costs and narrow product range of larger, more dedicated machinery.
To achieve this, the blow station has been heavily modified to incorporate two sets of blow molds mounted on a servo driven shuttle system. Since one-step molding cycle times are largely dependent on the preform molding time, the primary and final blow molds are able to mold PET containers that are hot fillable at up to 90C,subject to container design,whileoperating within the same cycle time as a conventionally molded container.
ASB for molding plastic jarsServo driven hydraulic pumps are fitted as standard, contributing to major energy saving and offering clean, quiet operation while all motions above the molding plane are either pneumatic or servo motor actuated, as in the case of the stretch / blow unit, ensuring that molded products are free from the risk of contamination.

For increased versatility, the machine is also capable of molding conventional containers for a wide range of applications including jars and in a wide range of molding materials. Injection clamp daylight has been extended up to 700mm for even greater flexibility in molding of longer preforms as is often required when molding non-PET resins, and an optional injection unit with increased capacity further extends molding flexibility.
At K2016 the machine will be demonstrated molding a 500ml PET ketchup bottle in five cavities suitable for hot filling at up to 87C.

 

ASB-70DPW v4 Improved Output & Efficiency

Very High Output of Small Containers in Various Resins ASB improved output and efficiency


K2016 represents the first time for ASB’s 4th generation ASB-70DPW to be exhibitedin Europe.Compared to the previous generation model, the v4 machine being demonstrated features a wide range of standard and optional equipment that provides lower energy consumption, greater productivity and improved reliability.
For energy saving, the optional servo hydraulic system provided power consumption savings of 30~40% over the same mold and cycle time, while the optional blow air recycle system has the capability to take exhausted blowing air back into the machine system for air cylinder operation thus saving energy at the operation (low pressure)air compressor.
ASB molding hotel style bottles at K2016The mechanical design of the blow station has been totally re-engineered permitting faster blow mold changeover times and providing enhanced reliability, while an enhanced mold changing system in all stations permits drastic reductions in overall mold change time. For a blow mold change, just 30% of the previous time is required while for a total and complete preform and blow mold change, around 50% of the previous time is required.
As with all ASB-70DPW models, the machine is dedicated to production of small bottles in molding configurations from 12 to 24 cavities and with the modified blow station, the maximum moldable container size has increased from 700ml to 1 liter along with numerous other cavitation improvements for other container specifications.

The safety door design has also been updated with a cleaner refreshed image that gives easier access for maintenance and also contributes to the reduced mold change times.
At K2016, the ASB-70DPW v4 will be molding a hotel style 30ml PET shampoo bottle in 24 cavities giving an output of 8,000bph.

 

ASB-12M/IBM Injection Blow Molding Version for Added Versatility

Compact Molding with Advanced Efficiency ASB injection blow moulding machine

The ASB-12M is one of the smallest but most versatile machines in ASB’s model line-up. For K2016 the exhibited machine is the ASB-12M/IBM variant which is dedicated to the production of small containers by the Injection Blow Molding (IBM) processand utilizes just two of the four molding stations in the regular machine. Although the IBM version is factory built for this process, should market changes demand it, the machine also has the capability to be re-engineered at the customer’s site to the standard four station operation for regular one-step injection stretch blow molding, acting as a safeguard to the operator’s investment.

ASBASB-12M/IBM will be molding a 46mm diameter polycarbonate lampThis IBM version of this model utilizes ASB’s unique vertical clamping system that allows the preform to be molded with no visible parting lines resulting in containers of particularly high visual quality for applications such as cosmetics and lamp covers.This model is equipped with servo hydraulic pumps as standard and for the exhibition, the machine will be fitted with real-time energy monitoring demonstrating just how little power this technology consumes.
At K2016 the ASB-12M/IBM will be molding a 46mm diameter polycarbonate lamp cover in 2 cavities for modern energy efficient LED bulbs in two cavities utilizing the IBM process with a side-gated cold runner system that gives the advantage of eliminating gating from the main body of the product, resulting in perfect optical quality where it matters.

 

For more information please visit the ASB Nissei Company Listing:

 

Go To ASB Company Listing >>

CONTACT




Nissei ASB South Africa (Pty)Ltd

Tel
+27 012 345 4924

E-mail
sales@nisseiasb.co.za

Website
www.nisseiasb.co.jp

Physical Address & Map
Unit 2, The Shields, 33 Victoria Link Street, Route 21 Corporate Park, Irene, Pretoria, 0062

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