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Page 1: PTI Preform Heating

4.4-21

Technology and Application of PET Training

Blowing Nomenclature

� Pre Blow - First Blowing Pressure

� PET requires a slow inflation rate to achieve designed orientation and stretch levels

� High Blow - Second Blowing Pressure

� High pressure is required to form the corners and quench material in base

� Flow controls change the rate of blowing

� All stations have flow controls for low air, some machines have flow controls on the high air system

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Technology and Application of PET Training

PackageDesign

MaterialProperties

PerformanceRequirements

ProcessRequirements

Preform Heating

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Page 2: PTI Preform Heating

4.4-22

Technology and Application of PET Training

Preform Heating

� Objectives:

� Understand the Nature of the source of IR Energy and the absorption of IR by PET preforms

� Learn why preforms tend to be hotter on the outside than on the inside after heating with IR

� Understand some of the limitations of the IR heating process

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Technology and Application of PET Training

Electromagnetic Radiation

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Page 3: PTI Preform Heating

4.4-23

Technology and Application of PET Training

IR Absorption Characteristic of PET

0.00

0.20

0.40

0.60

0.80

1.00

1.20

0.00 1.00 2.00 3.00 4.00 5.00 6.00

Wavelength (µm)

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Technology and Application of PET Training

IR Transmission Characteristic of PET

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Page 4: PTI Preform Heating

4.4-24

Technology and Application of PET Training

Output of Quartz Heater Elements

0.0E+00

2.0E+11

4.0E+11

6.0E+11

8.0E+11

1.0E+12

1.2E+12

0 1 2 3 4 5 6 7 8

Wavelength (µm)

2400 K

2000 K

1800 K

2200 K

1600 K

1400 K

Mo

no

chro

mat

ic R

adia

tin

g P

ow

er (

J/(m

2*s)

Spectral Radiation Distribution

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Technology and Application of PET Training

Sidel IR Heaters

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Page 5: PTI Preform Heating

4.4-25

Technology and Application of PET Training

Absorption of IR by PET Preform

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Technology and Application of PET Training

Absorption Properties Of PET

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.000 0.500 1.000 1.500 2.000

Wavelength, Microns

Slow Heating Resin

Medium Heating Resin

Fast Heating Resin

IR Absorption of PET

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.10

1.000 1.050 1.100 1.150 1.200 1.250 1.300

Wavelength (µM)

Slow Heating ResinMedium Heating ResinFast Heating Resin

PET Resins Vary In Absorption Properties

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Page 6: PTI Preform Heating

4.4-26

Technology and Application of PET Training

This Affects How Quickly Preforms Heat Up

Comparison of Heatup Rates

90

95

100

105

110

115

1 2 3 4 5 6 7 8 9 10

Inside to Outside Wall Position

Tem

pe

ratu

re a

tB

low

, De

g. C

Fast heating

Medium Heating

Slow Heating

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Technology and Application of PET Training

Oven

The oven is used to heat preforms:

� The function of the infrared oven is to bring the preforms to a temperature of between 90 and 120 degrees C before they are stretched and blown in the blow wheel.

� The oven boxes around the edge of the oven wheel are needed to reheat the preforms.

� Each oven box is personalized for the preform.� The oven can have different number of lamps to fit the need of

the preform.

� The oven box can be removed easily� It is connected to the power supply by a multi-pin plug.

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Page 7: PTI Preform Heating

4.4-27

Technology and Application of PET Training

Schematic of Heating System

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Technology and Application of PET Training

Oven

Courtesy of SIDEL

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Page 8: PTI Preform Heating

4.4-28

Technology and Application of PET Training

Oven

� The number of the lamps depends on the type of preform to be reheated and the bottle to be blown

� On each module there are two fans

� One which blows air towards the ends of the lamps

� A second fan forces air flow across for the preform to keep the outside of the preform from overheating.

� Neck shields with circulating water protect the necks bypreventing the infrared radiation from heating the finish

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Technology and Application of PET Training

More SIDEL Heating Hardware

Clean Reflective Plate 15 mm Lamp Holder

15 mm

Spacer �Lamp Out�

Spacer �Lamp In�

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Page 9: PTI Preform Heating

4.4-29

Technology and Application of PET Training

SIDEL Heating Hardware

�Dirty� Heater Side Reflector Clean Cooling Side Reflector

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Technology and Application of PET Training

Oven Adjustments

Courtesy of SIDEL

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Page 10: PTI Preform Heating

4.4-30

Technology and Application of PET Training

Air Circulation Through the Oven

� Air is blown on the finish after the preform leaves the first row of ovens and before entering the second row of ovens

� Air is blown across the preform to cool the surface of the preform

Courtesy of SIDEL

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Technology and Application of PET Training

100%

1mm 1mm 1mm 1mm

Example for A Wavelength Where 1 mm of PET absorbs 10%

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Page 11: PTI Preform Heating

4.4-31

Technology and Application of PET Training

100%

1mm 1mm 1mm 1mm

Example for A Wavelength Where 1 mm of PET absorbs 10%

90%

Layer Absorbs 10%

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Technology and Application of PET Training

100%

1mm 1mm 1mm 1mm

Example for A Wavelength Where 1 mm of PET absorbs 10%

90%

Layer Absorbs 10%

81%

9%

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Page 12: PTI Preform Heating

4.4-32

Technology and Application of PET Training

100%

1mm 1mm 1mm 1mm

Example for A Wavelength Where 1 mm of PET absorbs 10%

90%

Layer Absorbs 10%

81%

9%

73%

8%

Preform is Hotter Towards Outside

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Technology and Application of PET Training

IR Heatingin PET with 2000 Watt Lamps

25%450 Watts90 Volts1490 Degrees C

65%1160 Watts165 Volts1885 Degrees C

100%1800 Watts220 Volts2150 Degrees C

The length of the wave emitted by the infrared lamps is only optimal when the lamps have nearly reached their rated power

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Page 13: PTI Preform Heating

4.4-33

Technology and Application of PET Training

Explanation of Interaction of Heaters

� Intensity is greater in the center of the array.

� Each heater affects a large area.

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Technology and Application of PET Training

Zone ShieldQuartz Focusing Lens and Bracket

Special Hardware to Control Heat Zones Precisely

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Page 14: PTI Preform Heating

4.4-34

Technology and Application of PET Training

Material Distribution Example, Zone 3 Power to 55%

0.348mm / 0.0137″

0..332mm / 0.0130″

0.287mm / 0.0113″

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Technology and Application of PET Training

Material Distribution, Increasing Zone 3 Power to 99%

0.306mm / 0.0125″

0.364mm / 0.0143″

0.280mm / 0.0110″

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Page 15: PTI Preform Heating

4.4-35

Technology and Application of PET Training

Free Blowing at Different Temperatures

2 Liter 950

2 Liter 1100

2 Liter 1150

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Technology and Application of PET Training

Oven Lamp Control, Krones

Individual Lamps can be turned on and off. Lamp power can be adjusted in conditioning ovens.

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Page 16: PTI Preform Heating

4.4-36

Technology and Application of PET Training

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Technology and Application of PET Training

Power Output Curve to Regulated Ovens

� The oven will switch to the standby setting when all of the preforms have exited the oven

� The power will change to 100% when preform loading has been pressed

� The % of power will switch to the production startup setting after the oven has reached the loading set point and preforms will start to enter the machine

� The percent of power will change to adjust the heat to meet the preform set point (IN AUTO)

Courtesy of SIDEL

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Page 17: PTI Preform Heating

4.4-37

Technology and Application of PET Training

Oven Control

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Technology and Application of PET Training

Important Considerations in Reheating Process

� Material is heated from the outside to inside

� Cooling air is a process aid to prevent overheating of the outside

� Absorption characteristics of PET resins vary widely

� Heat zones in a quartz oven are highly �coupled�

� Adding and subtracting heat usually is a better process change to move material

� Running heat zones above 50% is generally a good practice

� Peak output wavelength is more favorable to penetrate PET

� Old quartz tubes tend to emit longer wavelength energy

� Ovens should be relamped on a bi-annual basis, more frequently for demanding applications such as preforms with high blow up ratios

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Page 18: PTI Preform Heating

4.4-38

Technology and Application of PET Training

Preform Heating Summary

� The purpose of the heat profile controls is to impart an axial temperature distribution on the preform which controls material distribution in containers

� The nature of this temperature distribution is very complex

� PET Preforms tend to be hotter on the outside than on the inside after heating with IR

� Single stage process tends to run a hotter preform than the two stage process

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Technology and Application of PET Training

Stretch Rod Movement

P10 (P ten)

Refers to the angle in degrees at the point where the stretch rod fully stretches the preform

P0 (P zero)

Refers to angle in degrees at the point where the stretch rod engages the preform

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