聚酯PET热灌装饮料瓶基础知识概述（PPT 43页)

1、,Range范围,Advantages效益,Specifics细节,Heat-resistant bottles热灌装瓶,Description描述,Specifics,Basic principle 基本原理 Hot-filling 热灌装 Pasteurization 巴氏杀菌 Purpose of heat-setting 加热设定的目的 Water uptake concept 吸水概念,Basic principle 基本原理,Blow-molding of PET bottles to withstand high temperatures with no deformation所

2、吹制的PET瓶必须能承受高温而不变形 standard bottles are deformed under the effect of heat from 60 C upwards 标准的瓶子加热至60 C 以上开始变形 adaptation of heat conditioning and blow-molding processes enables bottles to withstand temperatures of up to 88C 适当的加热条件和吹瓶工艺能使瓶子承受88C的温度 Application to the packaging of sensitive drinks

3、such as isotonics, fruit juices, teas etc. 应用作敏感饮料包装例如 等压、果汁、茶等 Hotfilling 热灌装 Pasteurization 巴氏杀菌,Hotfilling 热灌装,Operating method操作方法 The liquid is raised to a temperature enabling it to be sterilized 液体温度提升至能灭菌的温度 The bottle is filled at this temperature (up to 88C) 瓶子在这温度下(高至 88C)灌装 Sterlization

4、of the cap is obtained by contact with the hot liquid 瓶盖与热的液体接触进行灭菌 Gradual cooling 分段冷却 Specific stress factors 特殊的应力因素 Inflation then collapsing 膨胀后扁平 Local deformation 局部变形 Contraction 收缩,Inflation then collapsing膨胀后扁平,Rise in temperature of the material combined with mechanical stress 含有机械应力的材料温

5、度升高 material is softened, easily deformed 材料变软，容易变形 Hydrostatic pressure exerted by the liquid on the walls: bottle inflation 液体在瓶壁上产生向外的静压：瓶膨胀 Expansion of the air in the head area: increased inflation 顶部空气膨胀：增加膨胀 Effect of internal vacuum pressure resulting from the cooling of the liquid and the a

6、ir in the head area: phenomenon known as “collapsing” 由液体和瓶颈空气冷却而产生真空压力：已知现象如 “扁平”,Local deformation局部变形,Stress exerted locally during packaging 在包装过程中外界压力局部地作用 Mechanical stress exerted by the cap: risk of deformation 封盖的机械应力：变形的风险 Conveying of the filled bottles while still hot: deformation on con

7、tact with the transport and guiding equipment 已灌装的瓶输送静止受热：与输送链条接触和导向处变形 Contact of the unstretched neck with the hot liquid: the material becomes plastic, deformation is possible 未拉伸的瓶颈与热的液体接触：材料成为塑料态，有可能变形,Contraction 收缩,Deformation resulting from the intrinsic properties of the material 材料的固有特性导致变

8、形,Release under the effect of heat of the stress factors caused by stretching and which remain in the material after blow-molding 拉伸和吹塑后残留在材料里的应力在热量的作用下被释放 Deformation of the material which naturally tends towards a state in which the level of stress is lowest 材料的变形自然趋向于低应力水平的状态 “Memory” effect “记忆”

9、效应,Pasteurization 巴氏杀菌,Principle 原理 Filling at temperatures close to ambient 灌注温度接近于周围环境 Pasteurization tunnel. Feethrough of the bottle filled and capped under hot showers. A temperature of 75C is maintained in the core of the liquid for 10 min (25 min at 65C for carbonated drinks) 已灌注和封盖的瓶子通过有热喷淋的

10、隧道进行巴氏杀菌，液体中心温度维持在75C 、10分钟 ( 汽水为65C、25分钟) Cooling under showers at between 20 and 40 C 喷淋冷却至20 40 C之间 Specific stress factors 特殊的应力因素 Inflation膨胀 Contraction收缩,Inflation 膨胀,Rise in temperature of the material combined with mechanical stress 含有机械应力的材料温度升高 expansion of the air in the head area: infla

11、tion of the bottle 顶部区域空气膨胀：瓶子膨胀 Release of CO2 by carbonated drinks: increased inflation 碳酸饮料CO2 释放：增加膨胀 Internal pressure persists after cooling, despite the decrease in volume of the liquid. 冷却后内部压力持续，尽管液体体积减少,Contraction收缩,Deformation resulting from the intrinsic properties of the material材料的固有特

12、性导致变形,Release under the effect of heat of the stress factors caused by stretching and which remain in the material after blow-molding 拉伸和吹塑后残留在材料里的应力在热量的作用下被释放 Deformation of the material which naturally tends towards a state in which the level of stress is lowest 材料的变形自然趋向于低应力水平的状态 “Memory” effect

13、“记忆”效应,Purpose of heat-setting加热设定的目的,Improvement in heat resistance 改进耐热性 Increase in crystallinity增加结晶度,Prevention of contraction防止收缩 Limited generation of induced stress (process and preform design) 限制诱导应力的产生(生产和瓶坯设计) Relaxation of residual induced stress (molds) 残留的诱导应力松弛(模具),Increase in crystal

14、linity增加结晶度,Offset of the glass transition temperature 抵消玻璃化转变温度 Glass transition temperature raised to a level higher than the temperatures to which the bottle will be subjected 玻璃化温度升高至较高程度会影响瓶子 Enhanced development of spherulitic crystallization 球状结晶的发展增多,Operating range,Operating range,Glass tra

15、nsition temp. 玻璃化温度,Glass transition temp. 玻璃化温度,Development of spherulitic crystallinity球状结晶的发展,Enhanced heat-conditioning of the preform in the oven and hot mold 增大加热炉和模具内瓶坯的加热温度 High degree of crystallinity 提高结晶度 Preform undergoes powerful heat-conditioning before being quickly transferred for bl

16、ow-molding. 瓶坯进入吹模之前充分受热 Enhances the generation of spherulitic crystallization in the bottle on contact with the hot mold after the start of crystallization caused by bi-orientation. 当由拉伸引起的结晶开始后瓶与热模接触所产生的球状结晶增加 30 to 35 % compared with a maximum of 25 % for standard bottles 与最大结晶度为25%的标准瓶相比热灌装瓶结晶度

17、为3035% Reduction in the amorphous phase which is more sensitive to heat 调节热量减少无定型状态,Limited induced stress 限制诱导应力,Slow-speed stretching 较慢的拉伸速度 Stretching speed is sufficiently slow to enable the rearrangement of the molecular chains as deformation takes place 拉伸速度较慢使分子链重新整理是 发生变形的原因,Molecular 分子rea

18、rrangement limits the stress induced by stretching 拉伸限制诱导应力的产生,V1,V2 V1,Relaxation of induced stress诱导应力松弛,Blow-molding in hot molds 在热模内吹塑 The bottle is kept under pressure in the hot mold 瓶在热模内保压 Heat input increases the mobility of the molecular chains in relation to each other热量输入增加分子链彼此之间的活性 Re

19、arrangement of the molecular chains means they reach a low stress level 分子链的重新整理意味着达到一个较低的应力水平,“Natural ” relaxation in the walls of the bottle plated by pressure against the mold 瓶壁的“自然”松弛是由于逆反模具压力的结果 Stabilization by air-cooling 空气冷却稳定瓶子形状,Air-cooling 空气冷却,Air-cooling via the stretch rod 空气经过延伸棒进行

20、冷却 Fresh air under pressure introduced into the bottle 新鲜的压缩空气引入瓶内 Thermal stabilization 热稳定性 Fast cooling of the bottle wall 快速冷却瓶壁 Stabilization of the material 增加材料的稳定性,Stripping 脱模 Contraction of the bottle in the cavity 瓶在模腔内收缩 Disengagement of the bottle from the walls of the mold 瓶子脱离模具壁,Dise

21、ngagaement of the bottle walls from the mold 瓶子脱离模具壁,Aging Concept老化概念,Hydroscopic nature of PET PET的自然吸湿 Water uptake by PET 吸水 Lubricating effect 润滑作用 Water molecules enhance the relative movement of the molecular chains of PET 水分子增加PET分子链的相对运动 Consequences on bottle behavior结果在瓶子上的表现 The lubricat

22、ing effect enhances the natural release of the residual induced stress 润滑作用能增加残余应力的自然释放 Phenomenon of contraction 导致收缩现象 Heat-set bottle performance 加热设定瓶子性能 Water uptake conditions must be known 吸水情况必须已知,Description,Heat-conditioning oven 加热炉的调节 Blow-molding wheel 吹瓶轮 Bottle design 瓶子的设计,Heat condi

23、tioning 加热调节,SBO Series2 standard oven SBO第二代标准加热炉 Use of the standard oven made possible by the high degree of reserve power available 使用标准加热炉必须使用较高的电源功率 Specific adaptation 特殊的改变 Neck protection ramp 颈部保护斜面 IR cameras 红外线探温计 Special spindle bodies 特别的芯轴主体 Preferential heating 优化的加热,Protection ramp

24、s保护斜面,Independent ramps 独立的斜面 Neck protection rails can be adjusted independently of the heat unit ramps 颈部护拦能被加热装置斜面独立调节 Adjustment by wrench and quick release 用扳手调节和快速释放,IR cameras 红外线探温计,Temperature control 温度控制 3 temperature control cameras on the preform at the oven outfeed 在加热炉出口有三个温度计探测瓶坯的温度

25、1 camera at the outfeed of the blow-molding wheel 在吹瓶轮出口有一个探温计 Temperature measurement under the neck, on the body and the base 测量坯颈、坯身、坯底的温度 Feedback on lamp control from the heat units 信号送回加热装置控制灯管 Process temperature control to within one degree控制生产温度在一定的范围内,Spindles芯轴,Neck protection 颈部保护 Severa

26、l thermal stresses are caused by the nature of the process: heat-conditioning is more intense than in the standard process 生产过程中引起热应变；加热设定多于正常生产的设定 Spindle bodies are equipped with radiators and are ventilated芯轴有散热和排风装置 The risk of over-heating is limited by the improved heat exchange 加热炉的热量由改良的热传导所

27、限定 Prevention of any rise in neck temperature 防止颈部温度的上升,Preferential heating 优化的加热(option),Complex-shaped bottles 复杂形状的瓶子 The design of HR bottles is of “complex shape” type 热灌装瓶的设计是属于“复杂形状”的类型 Optimization of material stretching and distribution may require preferential heating of certain areas of

28、the preform 最佳的材料拉伸和厚度当然要求瓶坯各区的加热最优化 preferential heating obtained by “selective reflection”: the creation of shadow zones on the reflectors 最优化的加热由“可选的反射”获得：在反射镜上设置阴影区,Blow-molding 吹瓶,SBO Series2 blow wheel SBO第二代吹瓶轮 Combination of solenoid valve control with mechanical command and control, based o

29、n continuous rotary kinematics 由机器命令控制电磁阀和控制机器的连续运转 Special adaptation 特定的配合 Square GUPMs 方形的GUPMS Hot molds and air-cooling 热模和空气冷却 Four-stroke nozzle cylinder and nozzle with cannula 四冲程吹嘴汽缸和有套管的吹嘴,Hot molds and air-cooling热模和空气冷却,Hot molds: 热模 125 to 130 C on the mold surface 模表面温度125 130 C Tempe

30、rature-controlled oil circuit 油路控制温度 Air-cooling空气冷却 Stretch rod enables air-cooling inside the bottle 延伸棒能够用空气冷却瓶子内表面 Low-pressure (10b) fresh air inlet through the stretch rod 低压(10巴)的新鲜空气进入延伸棒 Rod is multipunched to localize cooling on critical areas 多孔的延伸棒局部冷却指定区域,Four-stroke nozzle 四冲程吹嘴,Bell n

31、ozzle controlled by 4-stroke cylinder 四冲程气缸控制的贝尔吹嘴 Retaining cannula and stabilizer 保持套管和稳定器 Axial centering of the preform on mold closure 瓶坯在闭合的模具上轴向定中 The bottle is retained between the base and the cannula on mold opening to ensure stripping is correct 瓶子保持在底模和套管之间确保脱模正确,The top and bottom of th

32、e bottle is retained during mold opening 开模时瓶子顶部和底部被保持,Preform and bottle design 瓶坯和瓶子设计,Optimized preforms 最优化的瓶坯 Reduced bi-orientation rate减少双向拉伸率 Body瓶身 Structure withstands hydrostatic pressure 结构能抵抗流体压力 Panels absorb deformation抗变形的板块 Waists and ribs prevent ovalization 腰部和肋骨防止出现椭圆形 Base底部 Rib

33、s prevent the deformation of areas of low-resistance (hotfilling and pasteurization for no-carbonated liquids) 肋骨防止耐热性较低而变形(热灌装和适用于非碳酸液体的巴氏杀菌) Petalod or spherical base depending on the stress level (pasteurization of carbonated liquids) 花瓣状和球形的瓶底有赖于应力水平(含碳酸液体的巴氏杀菌) Neck瓶颈 greater thickness较大的厚度 cry

34、stallized neck or heat-resistant insert 结晶或嵌入式耐热瓶口,Packaging performance 包装性能 Quality 质量 Productivity 生产能力 Versatility 多功能性 Know-how in bottle design 怎样设计瓶子,Advantages,Conditions条件,Examples例子,Mold temp.模温,Degree of crystallinity结晶度,Crystallized neck 结晶瓶口,Air-cooling 空气冷却,Fruit juice, tea-, coffee-ba

35、sed drinks 果汁，茶类饮料,120C to 135C,30% to 35%,Yes有,Yes有,75C to 85C,Isotonics等压,80C to 120C,25% to 30%,to be defined待定,to be defined待定,75C for 10 min.,Non-carbonated Drinks非碳酸饮料,Approx. 20C, 25%,Yes有,No无,65C for 25 min,Carbonated drinks* 碳酸饮料,Approx. 20C, 25%,Yes有,No无,Hot-filling 热灌装,Pasteurization 巴氏杀菌

36、,Performance性能,The temperature resistance performance characteristics are indicated in specific humidity uptake conditions (2 500 ppm) 耐热性能温度是指在特定的吸湿条件下（2 500 ppm) Output rates depend on process requirements and specific production factors 产量依赖于生产需求和特定的产品 ( * ) Specific bottle base may be required可以

37、按照需求设计瓶子底部,85C to 88C,Quality 质量,Process precision生产精确度 Precision of heating profile, including preferential heating if necessary 加热分布的精确度，包括是否需要优化加热 Quality of temperature gradients 温度梯度的质量 Optimized material distribution and stretching: potential weight reduction of containers 最佳的材料分布和拉伸：潜在减轻容器的重量

38、,Process regularity生产调整 Measurement of three temperature points on the preform: same thermal history file for all preforms 测量瓶坯的三个温度点；所有瓶坯的加热条件相同 Consistent process to within one degree for all preforms No loss of item quality 所有瓶坯在同一温度下生产，具有相同的质量,Quality质量,Process power生产动力 High power reserve 较高的备用

39、功率 Efficiency and precision of the process for a very wide range of preforms thanks to wide processability windows 瓶坯具有很宽的生产效率和精确度得益于有较宽的加工窗口 Neck protection 瓶口保护 Ventilated spindles: prevent over-heating of necks during heat conditioning 排风芯轴：防止加热调节过程中瓶口受热 Independently adjustable protection rails:

40、 efficiency and precision of protection 独立地调节保护挡板：保护效能和精密度 Blow-molding with bell nozzle: prevents any risk of deformation during blow-molding 贝尔吹嘴吹瓶：防止吹瓶其间有瓶口变形的危险 No deformation of necks possible 瓶口不会变形,Quality of appearance外观质量,Quality of cavity impression模腔压痕质量 Performance of heat conditioning e

41、nsures perfect cavity impression 加热调节的性能确保模腔压痕完美 Qualityof stripping 脱模质量 Efficiency of air-cooling 空气冷却的功效 Item retention for stripping保持脱模形状 Major importance due to the functional requirements of HR design 最重要的是所要求的热灌装瓶设计,Productivity生产能力,Blow wheel 吹瓶轮 Combination of mechanical and electronic con

42、trols based on continuous rotary mechanics 机械和电气控制相结合使机器能连续运转 Simple kinematics with a reduced number of transfers and active mechanical safety systems 减少传动数量的简单运转和灵活的机器安全系统 Reliability at high output rates 较高的产量可靠性 Blow-molding stations with reduced inertia 减少惯性的吹瓶位置 High output transfer of items a

43、t reduced inertia 减少惯性的传送臂 Optimum productivity with up to 1,200 containers per hour and per mold (mold output increased by 20 %) 最适宜的产量为1200个/小时/模（每模产量增加了20%）,Maximum mechanical output 1,400 bph per mold 最大产量为1400个/小时/模,Versatility多功能性,Quick-change concept for format changeover 快速换模概念 Reduced numbe

44、r of customization parts 减少用户零配件数量 Quick-Change customization parts, replaced fast with no tooling 无须太多的工具快速更换模具 Quick-change format 快速换模的方式,HR / Standard Versatility 热灌装/标准性能,Reversible adaptation of a standard machine 一台标准的设备 Standard oven 标准加热炉 Standard wheel标准吹瓶轮 Reconfiguration for standard bottles 标准瓶子的重新配置 Reconfiguration process (no work on oven required) 重新配置生产工艺(没有所要求的加热炉) Drain of the