Polyethylene

Terephthalate (PET)

• Processing Guidelines
• Troubleshooting Guide
Injection Moulding
Stretch Blow Moulding
• Recommended Tests
& Equipment
 INDEX
PROCESSING GUIDELINES
Drying
Drying Conditions
Dryer Startup
Dryer Specification
Injection Moulding
Resin Inlet Temperature
Barrel Temperature
Nozzle Temperature
Manifold Hot Runner Temperature
Injection Speed
Stretch Blow Moulding

TROUBLESHOOTING GUIDE
Injection Moulding
1) Short Shots
2) Sink Marks
3) Flash
4) Water Marks
5) Black Specs / Contamination
6) Flow Lines
7) Heat Splay
8) PET Inclusion
9) Concentricity
10) Crystalline Gate
11) Long Gate
12) Air Bubbles
13) Stress Pattern
14) Stringing
15) Cloudy Preforms
16) Hollow Gates
17) Discolored Preforms
18) Line Over Finish
19) Burnt Gates
20) Oval Finish
21) Gas Burns
22) High Acetaldehyde

Stretch Blow Moulding

1) Blown Finish
2) Sealing Surface Damage
3) Chocked Neck
4) Bent Neck
5) Hard Neck
6) Thin Shoulder
7) Hot Bottles
8) Excessive fill point drop
9) Pearlescence
10) Flat Sides
11) Deformation at mold parting lin
12) Chocked Body
13) Heavy Base Weight
14) Light Base Weight
15) Feet not fully formed
16) Hot Sides
17) Low Head Load
18) Low Burst Pressure (Body)
19) Low Burst Pressure (Base)
20) Poor Clearance
21) Fold in End Cap Line
22) Fold Around Stretch Rod
23) Cracked Base
24) Swung Gate
25) Stress Cracking
26) Explosion
27) Drop Test Failures

RECOMMENDED PET TESTS & EQUIPMENT

FOR DOWNSTREAM CONVERTERS

Intrinsic Viscosity
Acetaldehyde Analysis
Colour Measurement
Moisture Analysis
Headload Testing
Burst Testing
 PROCESSING GUIDELINES

THE processing guidelines set out below cover the two major processes involved
in the conversion of PET resin into preforms and containers, namely:

1. INJECTION MOLDING
2. STRETCH BLOW MOLDING.

The resin preparation conditions and barrel temperature profile recommended on

the injection
molder could also be used on extrusion barrel, in converting PET resin into
amorphous sheet.

DRYING :
Drying Conditions:
This is the first and most crucial step in converting PET resin into preform/
container/sheet. If the drying equipment is not adequate or is not functioning
efficiently then it is highly unlikely that you will produce an acceptable product.
The dried resin should have a moisture content not more than 50 PPM.
Recommended Drying Temperature: 160 - 180 °C Recommended Drying Time 5
- 6 hours.

Dryer Start-Up :
The time / temperature profile recommended when first starting the dryer or
starting from a major shut down is as below.

The first hour at 120 °C

The next two hours 150 °C
The next two hours 180 °C
Dryer Specification:
Able to heat air upto 200 °C
Able to deliver air flow rate in the order of 0.062 metre cube/ min per kg/ hr of
resin being processed.
Able to deliver hot dehumidified air with a minimum of -40.0 °C dew point.

Dryer Resin Level :

To give approximately 5 to 6
times the kg/hr capacity of the
injection molder or extruder in
case of sheet extrusion.

INJECTION MOLDING PROCESS:

This is the process by which the resin is converted from dried pellets to preforms.

Resin Inlet Temperature:

It is better to have a temperature of 160 -170 °C on the resin entering the feed
zone of the ex-truder.
Barrel Temperature Profile:
For other than water grade resin it is recommended to use a temperature of 265
°C in the feed zone gradually increasing towards the metering zone 280 °C. For
the water grade resin however, it is recommended to use a reverse temperature
profile, with highest temperature in the feed zone, say 280 °C and gradually
lowering towards the metering zone.

Recommended temperature :
265 - 280 °C

Nozzle Temperature :
Recommended temperature:
270 - 280 °C

Manifold Hot Runner Temperature :

Recommended temperature :
270 - 280 °C

Mold Cooling Water Inlet Temperature :

Recommended temperature :
7 to 8 °C

Injection Speed :
As required to fill the cavity with minimum shear and dependent on the gate size.
STRETCH BLOW MOLDING PROCESS:

The most commonly available stretch blow molding machines are the:
Single stage stretch blow molder ( preform & bottle made on the same machine).
They are AOKI, NISSEI, UNILOY, etc.

Two stage stretch blow molder (reheating and blowing of preforms made on
Injection molder).
They are SIDEL, KRUPP, SIPA, etc.

The processing conditions depend on the type of process used and the most
common parameters
to be controlled are:

o Preform Temperature.
o Re-heating oven profile and over all oven percentage.
o Oven sheilds o Bottle blowing speed, bottles/hour.
o Stretch rod speed o Air delay time o Pre-blow pressure.
o High blow time.
o High blow pressure.
o Blow mold cooling.
Optimizing of the above parameters depend on several factors such as :

o Preform design.
o Preform intrinsic viscosity.
o Preform infrared absorbing characteristics.
o Bottle design.
Troubleshooting Guide

Injection Moulding

1 Problem: SHORT SHOTS

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Injection Pressure low o Increase injection pressure

o Barrel temperature low o Increase barrel temperature
o Mould manifold temp. low o Increase mould manifold temperature
o Mould cavity temp. low o Increase mould cavity temperature
 o Injection speed low
o Back pressure low
2 Problem: SINK MARKS
POSSIBLE CAUSES
o Holding pressure low
o Holding time low
o High mold temperature
o Inadequate coolant supply
o Cooling time low
o Blocked venting
3 Problem: FLASH
POSSIBLE CAUSES
o Injection pressure high
o High injection speed
o Unwanted material in cores
o Unwanted material in splits
o Unwanted material in cavity
o High mold temperature
o High barrel temperature
o Clamping pressure low
o Increase injection speed
o Increase back pressure
o Clean vent on split, core and cavity
o Check that no foreign object is in gate
area.
o Check that the gate pin is moving all the
way back
POSSIBLE SOLUTIONS
o Increase holding pressure
o Increase holding time
o Decrease mould temperature
o Check cooling water
o Increase cooling time
o Clean vents on split, core and cavity
POSSIBLE SOLUTIONS
o Decrease Injection pressure
o Decrease injection speed
o Clean cores
o Clean splits
o Clean cavity
o Decrease mould temperature
o Decrease barrel temperature
o Increase clamp pressure
 4 Problem: WATER MARKS
POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Leaking hoses o Check hoses on mould for damage

o Leaking mould
o Insufficient dehumidification
o Mold enclosure inadequate
o Check mould for leaks
o Check that dehumidifier is working
properly
o Check that the machine enclosures
has no major gaps

5 Problem: BLACK SPECS /

CONTAMINATION
POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Contaminated resin o Check for resin cleanliness

o High residence time prior to o Clean the resin hopper
restart of the machine o Purge the barrel thoroughly on restart
o Degradation of resin o Reduce melt temperature
o Reduce back pressure
 6 Problem: FLOW LINES
POSSIBLE CAUSES POSSIBLE SOLUTIONS
o Injection pressure low o Increase injection pressure
o Mould temperature low o Increase mould temperature
o Barrel temperature low o Increase barrel temperature
o Injection speed low o Increase injection speed
o Drier inefficient o Check resin drier
o Back pressure low o Increase back pressure

7 Problem: HEAT SPLAY

POSSIBLE CAUSES
o Manifold and mold heater
Malfunction.
o Barrel temperature high
o Foreign matter in the gate
POSSIBLE SOLUTIONS
o Check temperature of mould cavity heaters
and Manifold
o Check barrel temperature
o Check that no foreign material is in gate area

8 Problem: PET INCLUSIONS

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Low barrel temperature o Check barrel temperature

o Low mould temperature o Check mould temperature

o Back pressure low o Increase back pressure

o Mixing head damage o Check that the mixing head of the

o Check valve damage screw or the screw is not broken.

of Inspect the check valve on the
screw (not Husky Machine)
 9 Problem: CONCENTRICITY
POSSIBLE CAUSES POSSIBLE SOLUTIONS
o Injection speed high o Decrease injection speed
o Injection core bent o Check that the injection core is not bent
and straighten it.

10 Problem: CRYSTALLINE GATE

POSSIBLE CAUSES
o Cavity heater malfunction
o Cavity temperature low
o Manifold temperature low
o Drier malfunction
o Hold pressure high
o Foreign material in gate
o Cooling insufficient
o Core cooling inadequate
o Fountain in core rod damage o Check water flow through the injection
POSSIBLE SOLUTIONS
o Check that the cavity heater is working
o Increase the cavity temperature
o Increase the manifold temperature
o Check that the drier is working
o Decrease injection hold pressure
o Check that no foreign object
obstructs the cavity gate
o Increase cooling time
core and cavity
o Check that the fountain in the injection
core is not bent
 11 Problem: LONG GATE
POSSIBLE CAUSES POSSIBLE SOLUTIONS
o Cavity heater malfunction o Check cavity heater
o Cavity heater low o Increase cavity temperature
o Gate valve malfunction o Check that the gate valve is working
o Shut-off nozzle malfunction o Check that the barrel shut-off nozzle is
o Short decompression time working
o Increase decompression time

12 Problem: AIR BUBBLES

POSSIBLE CAUSES
o Barrel temperature low
o Inefficient drying
o Low back pressure
o Barrel temperature
o Mixing head damage
POSSIBLE SOLUTIONS
o Check barrel temperature
o Check drier temperature
o Increase back pressure
o Lower temperature at last extruder zone
o Check extruder mixing head

13 Problem: STRESS PATTERN

POSSIBLE CAUSES POSSIBLE SOLUTIONS
o High injection pressure o Decrease injection pressure
o High shot size o Reduce shot size
o Long hold time o Decrease injection hold time
 14 Problem: STRINGING
POSSIBLE CAUSES POSSIBLE SOLUTIONS
o High cavity temperature o Reduce cavity temperature
o Low cooling time o Increase cooling time
o Low hold time o Increase injection hold time
o Inadequate coolant to cavity o Check water flow to cavities
o Gate valve malfunction o Check that gate valves are working

15 Problem: CLOUDY PREFORMS

POSSIBLE CAUSES
o Inefficient Drying
o Blocked drier filters
o Air leaks on the drier
o Air leaks on machine hoppers o Check for air leaks on machine hopper
o Low air flow to drying hopper
o Low process air temperature
o Barrel temperature low
o Insufficient drying
o Back pressure low
POSSIBLE SOLUTIONS
o Check drier temperature and dew point
o Clean drier air filters
o Check for air leaks on drier
o Check air flow to hopper
o Increase drier process temperature
o Increase barrel temperature
o Shut machine down for 1 hour and dry
material
o Increase back pressure
 16Problem: HOLLOW GATES
POSSIBLE CAUSES POSSIBLE SOLUTIONS
o Packing pressure low o Increase packing pressure
o Hold time low o Increase holding time
o Insufficient cooling time o Increase cooling time
o High cavity temperature o Lower cavity temperature
o Foreign material in gate o Check for foreign material in gate area.

17 Problem: DISCOLORED PREFORMS

POSSIBLE CAUSES POSSIBLE SOLUTIONS
o High barrel temperature o Lower barrel temperature
o High mold temperature o Lower injection mould temperature
o High drying temperature o Lower drier process temperature

18 Problem: LINE OVER FINISH

POSSIBLE CAUSES POSSIBLE SOLUTIONS
o Contaminated splits o Clean splits
o Low packing pressure o Increase packing pressure
o Insufficient packing time o Increase packing time
 19 Problem: BURNT GATES
POSSIBLE CAUSES POSSIBLE SOLUTIONS
o High cavity temperature o Reduce cavity temperature

20 Problem: OVAL FINISH

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Insufficient cooling o High core and cavity temperatures

o Hold time low
o Insufficient cooling
o Increase cooling time
o Increase injection hold time
o Check water temperature and water flow
to injection Mould
o Check temperature of injection cores
and cavities

21Problem: GAS BURNS

POSSIBLE CAUSES POSSIBLE SOLUTIONS
o High injection speed o Decrease injection speed
o Contaminated splits o Clean splits
 22 Problem: HIGH ACETALDEHYDE
POSSIBLE CAUSES
o High residual AA in resin
o High barrel temperature
o High back pressure
o High screw speed
o High injection speed
o High mold manifold temperature
o High nozzle tip temperature
o Long cycle time
o High extruder / screw cushion
o Low inlet resin temperature
o Unsuitable screw
POSSIBLE SOLUTIONS
o Check for resin AA levels
o Reduce the barrel temperature
o Reduce back pressure
o Reduce screw RPM
o Reduce injection speed
o Reduce mold manifold temperature
o Reduce cycle time
o Reduce cushion
o Increase inlet resin temperature
TROUBLESHOOTING GUIDE

Stretch Blow Moulding

 1 Problem: BLOWN FINISH

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Overheating of the finish area which o Move shield away from finish into a
allows blow pressure air to stretch the thicker part of the preforms taper
material. o Bring shield close to preform
o Oven ambient temperature to high o Increase oven exhaust
o Incorrect loading height, too much of o Reduce neck element heat
the finish is exposed to the elements

2 Problem: SEALING SURFACE DAMAGE

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Misalignment of the preform, blow
mould and blow nozzle usually caused
by poor transfer arm positioning.
o Blow mold position.
o Nozzle position.
o Realign transfer arm
o Realign blow mould or nozzle if
necessary

3 Problem: CHOCKED NECK

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Over stretching of the preform by
the stretch rod prior to blow.
o Low blow delayed or missing
o Reduce air delay time
o Reduce stretch rod pressure
o Move shield into a thicker part of the taper
o Increase heat in the body or base
o Increase low blow pressure
o Reduce heat in the neck
 4 Problem: BENT NECK

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Misalignment of the preform to the
mould or nose.
o Distortion below the flange
a) Insufficient mould cooling
b) One mould half with poor cooling
o Excessive material remained in the
neck and shoulder.
o Realignment of the preform to the
nose or mould.
o Reduce material thickness in the
shoulder by reducing heat in the body
o Increase high blow time
o Improve mould cooling

5 Problem: HARD NECK

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Initial stretching occurs too low o Reduce heat in the body and/ or base until
into the preforms taper. pearlescence occurs then increase neck
o Preform location incorrect temperature.
through oven. o Increase stretch rod pressure
o Air leak into preform before the o Increase air delay time
start of low blow. o Reduce low blow pressure
o Move shield into the thinner part of the taper
o Check height of preform though oven.
o Check for air leak through nose
 6 Problem: THIN SHOULDER

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Excessive stretching of the o Move shield into a thicker part of the
taper. Stations producing a smaller preforms taper.
low blow container will be first with o Reduce air delay time
the fault or the thinnest. o Reduce stretch rod pressure
o Poor shield positioning, allowing o Increase low blow pressure
excessive stretching of the thin o Reduce heat in the neck. If thickening
part of the taper. occurs below desired area Increase heat
below the neck element.

7 Problem: HOT BOTTLES

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Preform temperature above crystal
growth range for to long
o Insufficient cooling of the outside
surface for the amount of heat
absorbed by the P.E.T.
o Excessive equilibration time o
Preform wall thickness excessive
blowers.
o Reduce heat adjacent to the haze until
pearlescence is evident somewhere on
the bottle
o Reduce heat over all until pearlescence
is evident.
o Increase air circulation through oven,
increase blower speed, clean blowers.

8 Problem: EXCESSIVE FILL POINT DROP

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Low levels of orientation results in o Reduce over all perform temperature
the material not having enough allowing the bottle to be blown closer to its
strength to resist the pressure natural stretch limit. Under this condition
applied. slight pearlescence may be evident
 9 Problem: PEARLESCENCE

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Pearlescence results from o Material to thin - Increase heat
stretching of molecules other than where pearl is evident.
faster than they can respond o Where the pearlescent area may be allowed to
past it's natural stretch limit. stretch further increase heat at pearl.
Small tears appear on the o Increase overall preform temperature
material's surface. o Pearlescence opposite a swung gate (Refer
Swung Gate)
o Pearlescence on the bottle shoulder may be the
result of a blow air leak through nose from either
the low valve, high blow valve or stretch rod o
Reduce low blow volume, increase low blow time
and reduce low blow pressure.
o Ensure low blow bottle is not to large.
Excessive petal formation in low blow will cause
pearl in the petal area.
o Pearlescence in the body in the form of a ring is
the result of insufficient low blow.

10 Problem: FLAT SIDES

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Poor venting due to excessive o Ensure excessive mould parting does not
parting of the blow moulds allowing occur
air to be trapped along the mould o Increase low blow pressure ensuring
seams bottle diameter is close to blow mould size
o Low blow bottle too small. In this
case the volume of air trying to
escape during high blow is more
than the venting can allow.
o Low blow bottle blown to fast.
o Excessive high blow pressure
at the end of low blow to minimize air that
remains in the blow mould before high blow
starts.
o Reduce low blow pressure and extend
low blow time if the body of the bottle has
reached the mould
o Reduce high blow pressure

11 Problem: DEFORMATION AT MOULD PARTING LINES

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Pressure remaining in the
bottle when blow moulds open.
o Insufficient high blow cooling
time
o Material too hot and/or too
thick
o Inadequate exhaust time, check exhaust
valve activation.
o Increase high blow time or reduce
material thickness
o Reduce material thickness
o Reduce preform temperature

12 Problem: CHOCKED BODY

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Insufficient or no low blow o Increase low blow pressure

o Insufficient heat beside o Increase heat in the body

choke o Reduce heat in the base and/ or neck.

o Reduce air delay time
o Reduce stretch rod pressure
 13 Problem: HEAVY BASE WEIGHT

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Incorrect heating profile o Reduce heat in the body and/ or
resulting in a poor distribution of shoulder until pearlescence occurs
material, over stretching of the then increase heat at the base. Repeat
body or shoulder until the base weight is correct.

14 Problem: LIGHT BASE WEIGHT

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Poor heating profile o Reduce heat near the base of the preform
resulting in poor until pearlescence occurs then increase heat to
distribution of material, the shoulder
insufficient stretching of the and/or body. Repeat until base weight is correct
body or shoulder. o Increase air delay time
o Increase stretch rod pressure
o Reduce low blow pressure
o Reduce oven shielding of the taper

15 Problem: FEET NOT FULLY FORMED

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Insufficient high blow pressure. Rate of o Check high pressure. If possible.
high blow too slow, material movement stalls If station related check for high
before reaching the corners. Often as a blow leaks from nozzle or stretch
result of blow nozzle leak rod o Increase high blow time
o Insufficient high blow time. If adding high o Reduce base weight by reducing
blow time does not fix the problem look for preform temperature until
another cause. pearlescence is evident then
o Heavy baseweight. High blow pressure increase prefroms lower body
inadequate to move material into the corners temperature
o Excessive low blow pressure or time. If too o Check low blow bottle size.
much of the material will be left to form the Reduce if necessary
feet correctly. Corners are likely to be thin. o Fix swung gate
o Swung gate. Feet will not form in the
corners opposite the gate movement unless
extra heat is applied near the end cap.

16 Problem: HOT SIDES

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Inconsistent preform rotation o Check the preform for a drag marl. Ensure
through the oven oven shields are not touching the preform.
o Insufficient surface cooling Check collect, spindle or mandrel rotation
of the preform o Increase air flow onto the surface of the
preform

17 Problem: LOW HEADLOAD

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Insufficient orientation and/or
material thickness to deliver the
required physical strength
o Reduce over all preform temperature
o Reduce heat beside failure point
o Where failures occur between neck and
shoulder adjust shield into a thicker part of the
taper
 18 Problem: LOW BURST PRESSURE (BODY)

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Insufficient orientation (Too hot) o Reduce preform temperature
o Material to thin o Reduce body heat
o Confirmation
o Low IV

19 Problem: LOW BURST PRESSURE (BASE)

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Base of bottle blown too cold o Increase heat below the preform

producing excessive stress o Reset stretch rod clearance

o Stretch rod clearance too short o Reduce stretch rod pressure

o Excessive crystallinity at the gate

o Low IV
o Excessive stress in preform

20Problem: POOR CLEARANCE

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Preform temperature too high o Base weight correct or light, reduce heat
o Heavy baseweight beside and/or below the gate
o Endcap temperature too high o Base weight to heavy, reduce preform
o Aged preforms temperature
o Insufficient mould cooling o Increase high blow time.

o Excessive inherent preform stress

21Problem: FOLD IN BASE AT END CAP LINE

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Preform temperature to hot
o Preform endcap area to cold
o An excess of material in the vicinity
of the fold
o Lack or loss of low blow volume
o Excessive force applied by the
stretch rod
o Aged or stressed preforms
o Reduce heat in the areas other than the
base. If the fold remains after
pearlescence has formed. Heat may be
applied to the preform endcap area.
o Increase low blow pressure
o Reduce air delay time
o Reduce stretch rod pressure

22Problem: FOLD AROUND THE STRETCH ROD

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Over heating of the preform o Reduce heat or below the end cap area
end cap, material wraps around o Increase low blow pressure
the end of the stretch rod. In o Reduce stretch rod pressure
effect another thick/ thin
transition forms
 23Problem: CRACKED BASE

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Preform endcap too cold o Increase heat beside or below the gate
o Excessive stretch rod pressure o Reduce stretch rod pressure
o Clearance between the stretch rod o Check preform for excessive crystallinity,
and mould base too small if so change preforms.
o Thick crystallinity above the gate o Increase stretch rod, mould base gap

24Problem: SWUNG GATE

POSSIBLE SOLUTIONS POSSIBLE CAUSES

o First impacted mark is evident and is o Misalignment of the preform to the
not centered to the gate, an alignment mould, nozzle or stretch rod.
problem is usually the cause. Check for o Inadequate mould cooling, one half
misalignment. Ensure transfer arm only If the gate is centered to the stretch
locates preform in mould correctly. rod impact mark and yet not centered to
o Check blow mould cooling the mould base at the end of blow the
o If the first impact mark is centered, the stretch rod has lost control during blow.
stretch rod has lost control of the gate o Lower half of preform too hot
during blow. Often gate control is lost o Low blow pressure too high
due to excessive growth in length o Air delay time too short
during low blow. o Stretch rod length too short
Ideally growth should start high in the o Excessive stretch rod cushioning
preform reaching full diameter before o Worn stretch rod guides
full length if length is achieved o Excessive preform eccentricity
before diameter the rod must travel o Thick crystallinity near gate
further than normal to keep up.
o Reduce low bottle size
o Increase air delay time
o Reset stretch rod height
 25Problem: STRESS CRACKING

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Off center gates. Webs with the thinnest o Fix swung gate.
material will stress crack early. o Reduce preform temperature to
o Excessive post mould change. As pearlescence, reduce base weight if
clearance deteriorates web shape necessary. Increase high blow time
changes increasing the risk of stress o Reduce heat in the preform's lower body
cracking. o Line lubricants generally cause severe
o Excessive growth at the base cust line. stress cracking in all feet.
Temperature of the lower half of the o Increase base weight
preform's body is to high
o Chemical reaction by some line
lubricants.
o Low I.V. material
o Light base weight. Inadequate thickness
to resist movement.

26Problem: EXPLOSIONS

POSSIBLE CAUSES
POSSIBLE SOLUTIONS
o Hot bottles (Refer Hot Bottles)
o Refer Causes
o Folds in the base
o Light base weight
o Excessive post mould growth
o Low I.V.
o Chemical Reaction (Refer stress
Cracking)
o Contamination
o Air bubbles above the gate
 o Stress Cracking
o Cracked bases
o Excessive crystallinity

27Problem: DROP TEST FAILURES

POSSIBLE CAUSES POSSIBLE SOLUTIONS

o Preform end cap blown too cold o Increasing heat at the gate or below
o Light base weight without loosing base weight usually
o Excessive crystallinity above gate. improves drop test failure.
o Large air bubbles above the gate o Increase base weight.

RECOMMEDED PET TESTS & EQUIPMENT FOR

DOWNSTREAM CONVERTERS
Many preform and bottle pro- producers ducers will have QC laboratories
already, or may be thinking of setting up one if they do not have one already. The
following gives an indication of essential tests.

Intrinsic Viscosity
The intrinsic viscosity (I.V.) is a primary parameter that is monitored. The I.V. is a
measure of molecular weight. SABIC measures I.V. by solution viscometry. The
PET is dissolved in 3:2 phenol : 1,2 dichlorobenzene, at 25°C and 0.5%
concentration, and its flow time through a capillary is measured and compared
against the that of the solvent.
The higher the molecular weight of the polymer, the higher the flow time and
hence the I.V. This method requires high consumption of chemicals. However,
I.V. can also be measured by melt viscomtery. In this method, the polymer (resin
or preform) is powdered after cooling in liquid nitrogen, dried, then melted and
extruded through a capillary. The melt viscosity can be calculated from the flow
properties. As the melt flow properties are related to the molecular weight, a
correlation with the I.V. can be made. Consistency of drying is Melt Viscometer
very essential in getting good

results. The melt viscometer is r e c o m - mended for our downstream PET

customers for measuring the I.V. of resins and preforms. Melt viscometers that
can measure and give a readout of the I.V. are made by Lloyds Instruments
(U.K.) and Kayeness (U.S.A.).

Acetaldehyde Analysis
The acetaldehyde (AA) is an important property that needs to be monitored
specially for water packaging applications. The AA level in most commercial
resins is < 1 ppm. Most resin manufacturers today meet this target, and hence
the AA in the resin need not be measured by the down stream converter.
However, the preform AA and the AA in the bottle may be important. The preform
AA is measured by grinding the sample into a powder after cooling in liquid
nitrogen, by headspace gas chromatography (GC). There are critical AA levels
for water.

The bottle head space test is different. A freshly blown bottle is capped with a
septum and stored at 23°C for 24 hours. The AA migrates into the bottle
headspace. The AA concentration is measured by sampling the gas in the bottle
and injecting into a GC. It must be noted that Solution Viscometer Gas
Chromatograph
the AA achieved in the bottle depends on resin and injection moulding conditions.
The equipment needed for AA measurement is a GC with head space assembly.
In addition, a grinder for powdering the resin or
preforms is needed. Liquid nitrogen in addition to the glass vials and septa of the
GC are major consumables. Manufacturers of GC with head space assembly are
Hewlett Packard and Perkin Elmer.

Colour Measurement
The colour of the resin and preform may be measured for consistency.

The colour is measured in terms of L* (brightness), b* (yellowness or blueness)

and a* (redness or greeness) For resin, the material needs to be powdered.
Equipment for colour measurement is supplied by Hunter Lab. Colour in preforms
may be measured by crystallising the preform in an oven at 170°C for 30
minutes, powdering it and using the same equipment. Alternatively, preform
colour can be measured without sample reparation
using the ColorQuest XE spectrophotometer. Colour Spectrophotometer Sample
Preparation Acetaldehyde Analysis.

Moisture Analysis
is The moisture content in PET has to be reduced to < 50 ppm by drying before it
is injection moulding. If the moisture content exceeds this, there is a large drop in
the I.V. in the perform. Injection moulders generally have driers, but to check the
efficiency of the drier, it is worth sampling and analysing the resin after it is dried.
There are several bench top equipment available such as from Karl ischer, TA
Instruments and Arizona Instruments. Moisture Analyzer Burst Strength
Testing This equipment is widely used in the carbonated soft drinks industry by
the fillers, to assess the performance of the bottles in filling and withstanding
pressures of carbonated beverages, which are normally filled to 4 volumes of
gas. The burst pressure requirement is generally in the range of 140 to 170 psi
depending on the bottle size. This unit can apply the test pressure and hold it for
a given time and also measure the free volume expansion, the pressure could
also be applied in a ramped profile.

Head Load Testing

This unit - as the name suggests - is used to measure the axial load taken by the
bottle before failure. The speed of load application is critical and so is the axial
positioning of the bottles. The average acceptable values for carbonated bottles
are again in the order of 200 N (20 kg). This test once standardized could notify
the QC personnel of variation in material distribution on the bottle.
This test is crucial, as filled bottles have to take the top load in transportation and
storage of these bottles. Inadequate head could crush the bottles and causes
leakage of the beverage.

Burst Strength Tester

This equipment is widely used in the carbonated soft drinks industry by the fillers,
to assess the performance of the bottles in filling and withstanding pressures of
carbonated beverages, which are normally filled to 4 volumes of gas. The burst
pressure requirement is generally in the range of 140 to 170 psi depending on
the bottle size. This unit can apply the test pressure and hold it for a given time
and also measure the free volume expansion, the pressure could also be applied
in a ramped profile.