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1、西得乐的热定型工艺Sidel Heat Set Technology适用于敏感饮料 For sensitive beverages主讲人：兰尼 先生 Conducted by Mr. Ludovic LAINE,PET耐热瓶、无菌灌装及ACTISTM等离子工艺与应用技术交流会SIDEL TECHNICAL CONFERENCE ON HR-BOTTLE， ASEPTIC AND ACTISTM2001年12月4、5日 DECELMBER 4TH & 5TH, 2001 中国上海 Shanghai, CHINA,应用领域 Applications,适用于包装各类敏感饮料,如 For the pa
2、ckaging of sensitive drinks such as:果汁 Fruit juices茶 Teas健康饮料 Isotonic beverages其它饮料等 etc.,Titles,基本原理 热定型的基本原理 单轮吹塑工艺 轻体瓶 线性结晶炉 西得乐热灌装设备在亚洲的分布情况 西得乐在亚洲的联络方法,Basic PrincipleHeat Set fundamentalsOne wheel TechnologyLight weightingLinear crystal ovenReferences in AsiaContacts in Asia,基本原理 Basic princi
3、ple,主要工艺参数 Main parameters当前的灌装方式 Current filling methods:非连线热灌装 Off line hot filling连线吹瓶、灌装 Integrated blowing and filling operation热灌装瓶的热应力和机械应力 Thermal and mechanical stresses for hot filled bottles膨胀,继而负压变形 Inflation then collapsing局部变形 Local deformation收缩 Contraction,主要工艺参数 Main parameters,非连线灌
4、装 Off line filling operation,连线吹瓶、灌装Integrated blowing and filling operation,热灌装瓶的热应力和机械应力Thermal and mechanical stresses for hot fill bottles,灌装 Filling (70C to 95C),传输 Conveying,冷却 Cooling,变形 (材料变软)Distortions (material softening),静压 Hydrostatic Pressure,真空 Vacuum,封盖 Capping,局部变形 Localized distort
5、ions,热灌装 Hot Filling,灌装方式 Operating method将液体加热至一定的温度，这个温度可使液体消毒 The liquid is raised to a temperature enabling it to be sterilized 在此温度下进行灌装 (温度最高可达92C)The bottle is filled at this temperature (up to 92C)瓶盖通过与高温液体的接触而进行消毒 Sterilization of the cap is obtained by contact with the hot liquid 逐步冷却 Grad
6、ual cooling,特殊的应力因素 Specific stress factors膨胀，继而负压变形 Inflation then collapsing局部变形 Local deformation 收缩 Contraction,膨胀、继而负压变形Inflation then collapsing,液体的冷却及瓶颈部位的气体导致瓶子内部真空压力的产生：即通常所说的“负压变形”现象 Effect of internal vacuum pressure resulting from the cooling of the liquid and the air in the head area: p
7、henomenon known as “collapsing”,温度的升高及材料的机械应力 Rise in temperature of the material combined with mechanical stress,瓶颈部位气体的膨胀：加剧瓶子的膨胀 Expansion of the air in the head area: increased inflation,液体对瓶壁产生静压：瓶子膨胀 Hydrostatic pressure exerted by the liquid on the walls: bottle inflation,材料变软，极易变形 Material i
8、s softened, easily deformed,在包装过程中局部产生压力 Stress exerted locally during packaging,局部变形 Local deformation,未经拉伸的瓶颈与高温液体接触：材料塑化，存在变形的可能 Contact of the unstretched neck with the hot liquid: the material becomes plastic, deformation is possible,灌装后的瓶子在仍保持高温的状态下被输送：与输送和引导设备接触而导致变形Conveying of the filled bo
9、ttles while still hot: deformation on contact with the transport and guiding equipment,由于瓶盖产生机械应力：存在变形的风险 Mechanical stress exerted by the cap: risk of deformation,材料固有的特性导致变形 Deformation resulting from the intrinsic properties of the material,拉伸而导致的应力在高温下释放，但吹瓶之后材料中仍存在残留的应力 Release under the effect
10、 of heat of the stress factors caused by stretching and which remain in the material after blow-molding因材料本身具有一种保持应力较低状态的天然倾向而导致的变形Deformation of the material which naturally tends towards a state in which the level of stress is lowest“记忆”作用 “Memory” effect,收 缩 Contraction,Titles,基本原理 热定型的基本原理单轮吹塑工艺
11、 轻体瓶 线性结晶炉西得乐热灌装设备在亚洲的分布情况 西得乐在亚洲的联络方法,Basic PrincipleHeat Set fundamentalsOne wheel TechnologyLight weightingLinear crystal ovenReferences in AsiaContacts in Asia,热定型的基本原理Heat set fundamentals,PET的热特性 P.E.T. thermal properties结晶度对软化温度的影响 Influence of crystallinity on Tg材料处于不同状态时的特性 States propertie
12、s结晶的来源 Origin of crystals受热导致的结晶 Heat induced crystallinity拉伸导致的结晶 Strain induced crystallinity拉伸及受热共同导致的结晶 Combined strain & heat induced crystallinity吸湿性的影响 Influence of moisture pick up耐热瓶的吸湿过程 Kinetic of water absorption in HR bottles结晶度对水分吸收的影响 Effect of crystallinity on water absorption应力的释放 S
13、tress relaxation抑制应力的产生 Limited induced stress释放产生的应力 Relaxation of induced stress关于热定型 Heat set answering,PET的受热特性 PET thermal properties,材料处于不同状态时的特性 States properties,机械强度Mechanical resistance 热稳性 Thermal stability,对热十分敏感 High sensitivity to heat: 当接近软化温度时，PET变软 PET softens when approaching Tg记忆现
14、象：材料回到最初的状态Memory phenomena : material returns to its original shape,无序状态 Amorphous state,结晶状态 Crystalline state,导致结晶的因素Origin of crystals,温度升高Temperature rise,机械拉伸Mechanical stretching,球粒结晶Spherulitical crystallization,其它因素导致的结晶Induced crystallization,70,75,80,85,90,95,100,0,10,20,30,40,50,60,Xc %,
15、Tg on set (C),受热结晶 Heat Cristallisation,拉伸+受热 Orientation+ heat,软化温度 Tg = f (X),软化温度与结晶度Influence of crystallinity level on Tg,受热导致的结晶Heat induced crystallinity,PET的双向拉伸：对分子结构的影响Pet bi-orientation : effect on molecular structure,无序状PET Amorphous pet,结晶 Crystals,无序状区域 Amorphous area,拉伸方向 Strain direc
16、tion,拉伸方向 Strain direction,PET分子链的拉伸Pet chainsOrientation,拉伸导致的结晶Strain induced Crystallization,拉伸及受热共同导致的结晶Combined strain and heat induced crystallinity,受热HEAT,拉伸的结构 ORIENTED STRUCTURE,60 ,吸湿性与软化温度Effect of moisture absorption on Tg,40% Cristal.,无序状态 Amorphous,27% Cristal.,35% Cristal.,软化温度Tg C,吸湿
17、量 Moisture ppm,耐热瓶的吸湿过程Kinetic of water absorption in hr bottles (单轮吹塑瓶 - 可口可乐亚洲瓶型 1 wheel bottle - coca Asia shape ),59克 - 0.44毫米厚 59g - 0.44 mm thick,结晶度对水分吸收的影响 Effect of crystallinity on water absorption,拉伸吹塑时产生的应力，主要在于 Stresses are induced during stretch blow molding and depend on :瓶坯设计 Preform
18、 design拉伸速度 Stretching speed瓶坯温度 Preform temperature吹瓶速度 Blowing speed应力的释放对于瓶子合理温度下的热定型至关重要Stress reduction is essential to proper heat setting for hot fill application应力的释放比提高瓶子的结晶度更为重要 High crystallinity is not enough and even of lower importance than annealing:应力在无序状态区域被释放 Stresses are released
19、in the amorphous area,应力的释放Stress Reduction,热定型瓶Heat setbottle,无序状态材料占有很大比率High rate of amorphous material,变形 Distortions,材料熔化 Material melting,内部应力Internal stresses,应力的释放 Stress relaxation,结晶度提高Crystallinity increase,内部应力释放Internalstresses relaxation,耐热强度 Heat resistance,球粒结晶Spherulitical crystalli
20、zation+其它因素导致的结晶Induced crystallization,关于热定型 Heat set answering,95 C 灌装 FILLING AT 95 C,Titles,基本原理热定型的基本原理单轮吹塑工艺轻体瓶线性结晶炉西得乐热灌装设备在亚洲的分布情况西得乐在亚洲的联络方法,Basic PrincipleHeat Set fundamentalsOne wheel TechnologyLight weightingLinear crystal ovenReferences in AsiaContacts in Asia,单轮吹塑工艺One wheel technolog
21、y,瓶坯加热条件 Preform heat conditioning瓶子的吹制 Bottle blowing瓶子的设计 Bottle design设备的范围 Equipment range,瓶坯加热条件Preform heat conditioning,红外加热炉 Infra red oven温度保持一致 High consistency of temperature profile温度十分精确 High accuracy of temperature profile温度变化程度 Temperature gradients高效的温度变化程度 High effective temperature
22、 gradients瓶坯的加热情况 Preform heating profile通风系统 Ventilation system折光板 Reflectors转子 Spindles空气循环（备选）Air recycling (optional)温度控制 Temperature control吸湿 Moisture pick up吸湿的过程 Water absorption kinematic瓶坯加热的影响 Influence of reheat瓶口内气泡的产生 Incidence on free bubbles对瓶坯强度的影响 Influence on strain hardening结论 Co
23、nclusion,SBO二代设备标准加热炉 SBO Series2 standard oven 标准瓶坯加热炉具有高强度加热潜能 Use of the standard oven made possible by the high degree of reserve power available 线性加热炉的特点 Linear oven features瓶坯受热一致 Reheat consistency瓶坯受热精确 Reheat accuracy,红外加热炉 Infra Red oven,温度保持一致High Consistency Temperature Profile,独特的加热通道 U
24、nique lane灯管/瓶坯距离稳定不变 Constant distance lamp/preform瓶坯在受热过程中始终自转 Complete rotation in module闭环控制 Close loop control所有瓶坯受热过程相同 Same thermal history for all preforms,所有瓶坯温度一致 Same temperature for all preforms,所有瓶坯最初的受热温度相同Process start with all preform at same temperature 所有瓶坯的加热过程相同 Same process for
25、all preform,温度十分精确High Accuracy Temperature Profile,高强度加热潜能 High power reserve- 第1加热区为3000瓦 3000 w / Zone 1- 第2至9加热区为2500瓦 2500 w / Zone 2 to 9 高效加热 Profile reached actively分为9个区域对瓶坯不同部位进行加热 9 zones splitable profile瓶坯受热部位热量分布精确 High accuracy temperature profile加热区间距累进式排列 Progressive pitch rack对各种坯型
26、均可进行优化加热 Optimized lamps distribution for any type of preforms 由能量控制加热 Power regulated lamps根据瓶坯和瓶子的规格进行优化加热 Profile optimized according to preform and bottle specifications,温度的变化程度Temperature Gradients,第1步 Phase 1,第3步 Phase 3,第4步Phase 4,第2步 Phase 2,整个过程分为4个步骤 Process broken down into 4 phases有效的温度变
27、化程度 Gradients reached actively温度变化程度控制工艺质量和效率 Control of quality and efficiency of process regarding to gradients,高效的瓶坯加热Highly Effective Temperature Gradients,整个过程分为4个步骤 Process broken into 4 phases 热量穿至瓶坯中心部分，瓶坯外部均保持通风 Heat rays penetrate to the core, exterior of preform ventilated 效率完全控制 Efficien
28、cy fully controlled,瓶坯加热 Preform heating profile,内部 INSIDE,外部 OUTSIDE,内部 INSIDE,外部 OUTSIDE,低气流量 LOW AIR FLOW,高气流量 HIGH AIR FLOW,瓶壁Bottle wall,int,ext,Preform section,Preform section,i,ext,通风系统 Ventilation system,风扇送风 Inlet Feeding by Turbines压力风仓 Over pressurized chambers 风量可调 Regulated feeding沿瓶坯加热
29、炉装有匀速送风口 Uniform ventilation speed along oven banks,折光板 Reflectors,100%折光 S2 (100% reflection),Body,Neck,with no reflector,110,110,0,-,15,S2 reflectors,(100% reflection),121,Air Speed (m/s),internal,TC,external,TC,TC,difference,11,13,114,-7,INFLUENCE OF REFLECTORS ON PREFORM,TEMPERATURES (INTERNAL/E
30、XTERNAL SKIN),空气循环 Air recycling (备选 optional),完全一体 Fully integrated 有助于对瓶坯温度作细微调整Help to fine tune preform temperature自动控制 Automatic control,小范围Small range,中等范围及大范围 Medium range & Big range,转子 Spindles,保护瓶口 Neck protection结晶和非结晶瓶口均可与转子配合工作 Spindles can accept both crystallized and amorphous neck fi
31、nish在加工非结晶瓶口时,由于热定型瓶坯加热炉的热量较标准加热炉的热量大,会对坯口产生多项热应力. In case of an amorphous neck finish, several thermal stresses are caused by the nature of the process: heat-conditioning is more intense than in the standard process转子配有散热装置并可通风 Spindle bodies are equipped with radiators and are ventilated改进后的散热装置抑制
32、了过量加热的风险 The risk of over-heating is limited by the improved heat exchange瓶口得到很好的保护 Prevention of any rise in neck temperature,在瓶坯加热炉的出口设有3台温度监测仪 3 temperature control cameras on the preform at the oven outfeed温度监测仪监测以下3个部位的温度:支撑环下,坯身,坯底 Temperature measurement on the neck amorphous neck), on the bo
33、dy and the base监测仪将数据反馈给灯管温度调节装置 Feedback on lamp control from the heat units温差在1度以内 Process temperature control to within one degree,温度控制 Temperature control,59克瓶坯 - 4.1毫米厚 59g preform - 4.1mm thick,瓶坯对水分的吸收Water absorption in preforms 22C 湿度 50% at 22C - 50% RH,Influence of water on I.R.absorption
34、,Calorimetric,Temp. (C),Camera,600 ppm,101.8,113.2,1400 ppm,104.7,114.2,3600 ppm,106.6,113.2,瓶坯在同样条件下重新加热 Preforms reheated in the same conditions,Temp. (C),110,280,60,160,0,100,200,300,400,500,1400,3600,Moisture absorption (ppm),Volume increase / 500ppm preforms (ml),lubricant effect,extra IR absor
35、ption,41克瓶坯 - 4.1毫米厚41g preform - 4.1 mm thick,0 ppm,1400ppm,3600ppm,吸湿对气泡的影响Incidence of moisture pick-up on free blow bubbles,吸湿的结论Conclusion on moisture pick-up,西得乐的专门研究和取得的经验表明 Specific studies carried out by Sidel and experience are showing :,1000至1500 ppm的湿度甚至有助于 1000 to 1500 ppm of moisture a
36、re even of some help in :瓶坯的重新加热 Preform reheat结晶 Crystallization kinetics应力的释放 Stress annealing,不能控制瓶坯的温度比水的润滑作用对瓶坯的影响更为严重 A lack of control in preform temperature is a lot worse than the lubricant effect of water,瓶坯的性能只有在恶劣的吸湿条件下放置6个月后才会下降Preforms characteristics are only dropping after a 6 months
37、 storage in bad moisture conditions,良好及合理的存储条件 (FIFO,PE袋等)足以确保瓶坯质量的一致Good and reasonable storage conditions (FIFO, PE bags, .) are enough to ensure a constant preform quality,瓶子的吹制 Bottle blowing,吹塑 Blow-molding热模 Hot molds中央控制系统 / 数据处理控制系统 (备选)P.C.C. reading / Statistical Process Control (option)吹嘴
38、 Blow nozzle空气冷却 Air cooling标准吹塑曲线 Standard blowing curve优化的循环时间 Optimized cycle time温度控制 Temperature control多样性(HR/HPR/CSD) Versatility HR / HPR / CSD陈化概念 Aging concept,吹 塑 Blow-molding,SBO二代吹塑转轮 SBO Series2 blow wheel根据连续轮转机械运动原理,将螺线阀与机械命令相结合 Combination of solenoid valve control with mechanical c
39、ommand and control, based on continuous rotary kinematics吹塑转轮的特点 Blow wheel features 方型模具支撑架适用于吹制最大容量为2升的耐热瓶，与CSD模心和方型模具兼容（最高速度1200瓶/小时/模） Square GUPMs up to 2 L HR bottles, CSD shell and square mold compatible (up to 1200 bph/mold)圆型模具支撑架适用于吹制最大容量为0.6升的瓶子,与CSD模心兼容 (最高速度1530瓶/小时/模) Round GUPMs up to
40、 0,6 L bottles, CSD shell mold compatible (up to 1530 bph /mold)热模吹塑及空气冷却 Hot molds and air-cooling优化的输送装置和模具驻留时间 Optimized transfers and mold residence time,热模 Hot molds,模具表面温度达135 to 145 C（模温机达145至155 C) 135 to 145 C on the mold surface (about 145 to 155C on heat regulator)温控的油管 Temperature-contro
41、lled oil circuit带有安全关闭系统的快速热油连接Quick oil connection with safety closing system快速更换（模具） Easy change over (shell mold),受热时，分子链的结构重新调整以达到较低的应力水平。When heat energy is added, the structure of the molecular chains is rearranged to reach lower stress levels.,中央控制系统 （备选）P.C.C. Control (optional),由中央控制系统集中控制吹
42、瓶及温度Blowing & temperature control are centralized on the P.C.C.,吹 嘴 Blow nozzle,在吹塑过程中，瓶口始终在罩式吹嘴的保护之下而不会 变形。吹嘴的两步式嵌入使瓶坯取中定位和安全脱模效果更佳。To avoid deformation, neck remains under isobaric condition during blowing. 2 steps movements allow better centering and holding during stripping.,空气冷却 Air cooling,空气冷
43、却功能由中央控制系统激活。Air cooling is activated from the P.C.C.确保吹塑过程的稳定和最后的收缩。 Insure stabilization and shrinkage at the end of the blowing process.避免了瓶子的粘黏现象。 Avoid bottle sticking phenomena.,空气冷却通过瓶子内部的拉伸杆完成Stretch rod enables air-cooling inside the bottle低压空气（10巴）由拉伸杆导入 Low-pressure (10b) fresh air inlet
44、through the stretch rod拉伸杆上有多个冷却空气排放孔，可对关键部位进行局部冷却 Rod is multi punched to localize cooling on critical areas,空气冷却 AIR COOLING,排气 EXHAUST,主要吹塑 MAIN BLOW,预吹 PREBLOW,时间 TIME,压缩空气 P,40巴 40 b,单轮工艺典型的吹塑曲线Typical Blowing Curve for One Wheel Process,812巴812b,主要的活动 Main movements:模具开合 mold opening / closing
45、模具上锁与解锁 mold locking / unlocking 吹嘴的上下运动 blow nozzle up/down预吹 pre-blow主要吹塑 main blow空气冷却 air cooling最终的排气 final exhaust,优化的循环时间 Optimized cycle time,考虑到最为恶劣的灌装条件（连线或非连线），吹瓶机可以进行优化。为提高循环用时，吹瓶速度将降低，结晶度增加，应力降低。In order to achieve most severe filling condition (in or off-line), blow molding machine can
46、 be optimized. Output rate will be reduced to improve cycle time, increasing crystallinity level and reducing stress.,为优化生产，拉伸凸轮需要更换 In case of optimization, stretch cam has to be changed,43,30,272,70,44,00,0,46,2,87,0,46,41,80,18,90,18,90,50,30,0,44,0,20,0,20,0,53,36.80,287.10,36.50,3.02,0.39,0.38,
47、182.20,47,90,1.92,0,50,SBO20标准热定型设备的用时表（950瓶/小时/模）Timing chart of the SBO 20 standard HR 950B/H/M,22,40,301,10,0,24,3,17,0,38,30,30,285,70,44,00,0,32,3,01,0,46,26,80,18,90,47,90,18,90,50,30,0,28,0,20,0,20,0,53,36,50,197.20,2.07,0,50,优化的SBO20热定型设备的用时表（950瓶/小时/模）Timing chart of the SBO 20 optimized HR
48、 950 B/H/M,多样性(HR/CSD/HPR)Versatility HR / CSD /HPR,SBO二代吹瓶设备具有高度灵活性，可从一个品种转到生产另一个品种。因为 Experience the high flexibility of our series 2 blower to switch from one bottle application to the other. With:,水环路的快速更换连接系统（带气密装置）。快速可靠，省时节能。 Quick change connectors on hydraulics circuits (equipped with self o
49、bturator device). Fast and reliable, to save time and energies. 模具可快速方便的拆卸 Shell molds for quick and easy handling. 所有个性化部件均配有快速更换系统（转子、转轮、导轨、机械手、拉伸 杆、底模等）Quick change system on all personalization parts (spindles, wheels, guides, grippers, stretch rods, base molds, .). 中央控制系统控制冷却功能的开启和关闭。只需按触摸屏上的按键
50、即可。 P.C.C. control for enabling /disabling cooling feature. By single pressure on a button in the touch screen. 生产工艺的配置 Process configuration: 将工艺程序从硬盘下载到控制面板上（红外加热炉、吹瓶、速度、循环时间等）download process recipes from hard disk to P.L.C. (I.R. oven, blowing, speed, cycles times,.).,陈化概念 Aging Concept,PET的吸湿性
