21 Tips For Maintaining The Bottle Blowing Machine

Acquiring a bottle-blowing machine and maintaining it together is essential for the optimum working and lifetime of the machine. These systems are crucial for producing quality PET bottles, and their effectiveness greatly influences overall productivity. Appropriate maintenance avoids unforeseen stoppages of machines and improves productivity by reducing time loss. With the correct set of practical maintenance tips, machine operators and technicians can guarantee that the machines operate in the best conditions regarding bottle quality while preventing machine wear. This blog contains 21 tips to ensure these machines remain in a good state of functioning. In other words, this post is about blowing machines and how to keep them in good working condition.

Daily maintenance (14 Tips)

1. Check the Clamping Device: Inspect the device to ensure it operates smoothly and consistently. It is vital for maintaining the integrity and shape of the bottles. Look for any signs of misalignment or wear, and listen for unusual noises that might indicate mechanical issues.
2. Check the Heating Coil (Heating Plate): Verify that the heating coil is firmly fixed. Examine the wiring for frayed or exposed wires that could lead to short circuits. Consistent heating is crucial for uniform bottle formation, so address any irregularities promptly.
3. Check the Motor Oil Pump, Pipes, and Valves: Conduct a thorough inspection for oil or water leaks, which can affect machine performance. Leaks can lead to insufficient lubrication or cooling, damaging machine components. Regularly tightening connections can help prevent this issue.
4. Check the Oil Level in the Oil Tank: Ensure the oil level is within the designated markers. Too little oil can result in inadequate lubrication, while too much can cause spills and messes. Top up the oil as necessary with the manufacturer-recommended type.
5. Check the Cooling Water and Mold Cooling Medium: Confirm that the cooling water has a steady flow and has no blockage in the system. Proper cooling prevents overheating and ensures the molds maintain the right temperature for optimal bottle quality.
6. Check the Motor Oil Pump, Pipes, and Valves for Abnormal Noise: Listen for any unusual sounds emanating from the oil pump and its components. Abnormal noise could indicate a mechanical fault or impending failure, which requires immediate attention to avoid downtime.
7. Check the Oil Temperature: After several hours of operation, measure the hydraulic oil temperature. It should be between 35°C and 50°C. If it exceeds 60°C, shut down the machine to allow it to cool, as excessive heat can damage the system.
8. Check System Pressure: Monitor the system pressure to ensure it remains within the recommended range as specified in the machine’s manual. Deviations can affect the quality and consistency of the bottles, potentially leading to defects.
9. Check the Extrusion Unit Components, Manifold Assembly, and Die Head: Look for any signs of glue or resin leakage around these components. Leakage can indicate a breach in seals, requiring replacement to maintain product quality and machine efficiency.
10. Check the Closing Knife Assembly: Inspect the guide rods for wear and verify that the gap between the front and rear knives is set correctly. Ensure that the knives are being effectively cooled to prevent overheating, which can lead to dullness and inefficiency.
11. Check the Pneumatic System: Test the system to confirm it functions correctly. Any faults could impair the machine’s ability to form bottles properly. Listen for air leaks and check the pressure levels to ensure optimal performance.
12. Check the Central Lubrication System: Ensure all moving parts receive adequate lubrication. The central lubrication system should distribute oil evenly to reduce friction and wear, prolonging the lifespan of components.
13. Check the Stability Limit Switch: Verify that the limit switch is intact and triggers as designed. This switch is critical in maintaining operational safety and precision, preventing overextension that could damage the machine.
14. Check the Main Oil Circuit On-Off Valve and Spool Feedback Input: Ensure the valve operates smoothly and the feedback input is responsive. Proper functioning of these elements is essential for maintaining pressure control and ensuring consistent machine performance.

Regular maintenance (3 Tips)

1. Cleaning the Inside of the Machine: Begin by thoroughly cleaning the barrel, screw, die head assembly, and forming mold of the extruder. This process involves removing any residue or build-up that can affect the machine’s performance and the quality of the bottles. Use appropriate cleaning agents and brushes to ensure all components are contaminant-free. Regular cleaning prevents blockages and maintains the smooth operation of the machine.
2. Replace Worn Parts: Conduct a detailed inspection to identify worn components, such as the mold clamping device and heating coils. Over time, these parts can degrade, leading to inefficiencies or defects in bottle production. Replace parts showing wear with manufacturer-approved replacements to ensure the machine operates at peak efficiency. Regularly replacing worn parts helps prevent unexpected breakdowns and prolongs the machine’s lifespan.
3. Check the Electrical System: Regularly inspect the electrical system for signs of wear or damage. This includes checking all wiring connections, control panels, and electronic components for loose or burnt wires. Functional electrical systems are crucial for the safe and efficient operation of the machine. Use a multimeter to verify electrical integrity and address any issues promptly to avoid potential malfunctions or safety hazards.

Common faults and solutions (5 Tips)

1. Bottles Cannot Be Removed from the Mould After Blowing: If bottles are not ejecting from the mold, the first step is to check the exhaust time setting. An incorrect setting can lead to improper air release, causing the bottles to stick. Inspect the exhaust valve for functionality by checking the spring and seal. If the spring is worn or the seal is damaged, the valve might not function correctly, requiring replacement or adjustment to restore proper operation.
2. Bottles Are Pinched: The issue may lie with the manipulator’s positioning when bottles appear pinched. Ensure the manipulator is correctly aligned with the mold. Misalignment can cause the bottles to be improperly gripped or released. Adjust the manipulator’s position according to the machine’s calibration instructions, ensuring it moves smoothly and precisely in sync with the other components.
3. No Filling at the Filling Level: If no filling is occurring, begin by checking the material level in the hopper. Ensure that adequate material is available for processing. Next, verify that the control contactor receives power; a power issue can prevent the motor from running. Additionally, check if the motor is powered and operating without load, as a lack of load may indicate a mechanical or electrical fault preventing normal operation.
4. Feeding Stuck in the Feeding Tray: When feeding gets stuck, start by checking the length and weight of the preforms to ensure they are within specified limits. Variations can cause jams in the tray. Also, inspect the lifting belt to confirm it is not stuck or obstructed. Remove any debris or obstructions and ensure the belt is properly tensioned and aligned to facilitate smooth movement of preforms through the system.
5. Other Common Troubleshooting Tips: Troubleshooting PET bottle-blowing machines involves identifying wear signs like increased vibration and unusual noises and inspecting components for wear or misalignment. When malfunctions occur, shut down the machine, inspect critical components, and check electrical connections. For product quality issues, adjust machine settings related to temperature, pressure, and cycle time and ensure mold temperatures and blower pressures are correct. Regular monitoring and adjustments help maintain production standards and reduce waste.

How to Clean the PET Bottle Blowing Machine Effectively?

The best way to maintain the PET bottle-blowing machine is to remove the important parts to facilitate their cleaning with nonabrasive cloths and brushes while avoiding strong chemicals that would cause damage and contamination. Cleaning intervals are associated with production outputs. In a clean environment, weekly cleaning is recommended to produce up to three thousand bottles. For high-volume machines, quick daily cleaning is more practical. Dilute gentle pH cleaning agents to aid in maintaining the machine while avoiding abrasive or caustic chemicals.

What Can Be Inspected in a PET Bottle-Blowing Machine?

It is necessary to initiate a routine maintenance culture on a PET bottle-blowing machine to enhance its operation and reduce breakdowns. Some focal points requiring close monitoring include the moving parts, air compressors, and operational zones. This includes looking at the moving parts to see if they are worn out, well-oiled, or well-positioned. Make it a point to inspect the heating elements, electrical wires and connections, pressure, and any safety features to lessen the chances of a breakdown. Ensure that the air compressor’s air intake filter, pressure settings, hoses, fittings, oil levels, and temperature meet the operational requirements.

How to Lubricate a Blow Molding Machine Properly?

Also, appropriate lubrication on certain components in a blow molding machine is crucial as it guarantees free movement and increases life span of the machine. Notable areas that need machine oil include the toggle system, clamp rails, moving platens, gear assemblies and linear bearings. Polyalphaolefin (PAO) oils are suggested since they have a stable thermal behavior. The recommended lubrication schedule is dependent on the instructions provided by the manufacturer. It is done daily to weekly, depending on the intensity of the usage, as this will prevent any friction and wear and increase efficiency of the machine.