Station 1 - Preform Injection

Plastic granules are melted in the barrel and injected into the injection cavity under controlled pressure. The bottle neck and thread geometry are formed precisely in the injection mold. The injection mold opens and the mandrel carrying the hot preform transfers to Station 2 via the rotary turret.

Station 2 - Blow Molding

The hot preform is inflated by compressed air from the mandrel core. The bottle shape is determined entirely by the blow mold cavity. Air inflates the preform outward against the cooled mold walls, and the bottle assumes its final dimensions. The mold opens and the turret advances to Station 3.

Station 3 - Ejection and Conveying

The finished, cooled bottles are stripped from the mandrels and discharged onto the outfeed conveyor. Since all three stations operate simultaneously, the cycle repeats continuously. There is no secondary operation, no deflashing press, and no bottle reheating required - the three operations share one cycle clock.

Full European-Style Steel Frame

CNC-machined monolithic machine bed and platen mounts ensure parallelism between injection and blow clamping platens. Tie-bar surfaces are induction-hardened. The EP80 clamping force is 20-30% above equivalent-tonnage competitors due to the boosted pressurized clamping structure.

Bimetallic Screw and Barrel

The plasticizing unit uses a bimetallic-lined barrel and a hardened alloy screw rated for glass-fiber and mineral-filled compounds. The EP80 screw diameter of 55 mm at 22:1 L/D delivers thorough homogenization with a 466 g shot capacity, covering the full range of bottle weights for this tonnage class.

Proportional Valve Hydraulic Control

Both injection pressure and blow pressure are regulated through servo-proportional hydraulic valves. This allows multi-stage injection profiling (fill velocity, switchover, pack pressure) for thin-walled preforms, and precise blow pressure ramp control that eliminates the radial webbing defects common in single-stage blow valve systems.

PLC Touch-Screen Control System

The EP80 control panel runs a full-color PLC touch-screen with parameter recipe storage. All process variables - temperatures, pressures, velocities, timings - are set and monitored from a single screen. Alarm history, production counters and fault codes are logged and displayed in real time.

Optimized Hot Runner System

The injection mold hot runner manifold is designed for zero dead-zone flow, ensuring gram weight deviation across all cavities is minimized. Temperature control accuracy to plus or minus 1 degree prevents degradation of heat-sensitive materials and is essential for consistent clarity in transparent containers.

Special Core Rod Design

The mandrels (core rods) feature internal cooling channels that reduce core temperature between the injection and blow stations, accelerating the cooling phase. Fast-cycle mandrels enable the EP80 to achieve a 4 S dry cycle without sacrificing preform cooling uniformity or dimensional stability.

Pharmaceutical Industry

• Eye drop bottles (LDPE, 5-30ml)
• Oral tablet and capsule bottles (HDPE, 30-500ml)
• Nasal spray and pump bottles (PP)
• Liquid medicine bottles with child-resistant caps
• Vaccine and reagent vials (LDPE, 1-20ml)
• GMP-grade amber and white HDPE pill bottles

Cosmetics Industry

• Roll-on deodorant applicator bottles (PE, 50-100ml)
• Mascara tubes and wand bottles (PP, 5-20ml)
• நகப்பூச்சு பாட்டில்கள் (PS, 10-30மிலி)
• Lotion and serum pump bottles (PCTG, 30-200ml)
• Wide-mouth cream jars (PP/PS)
• Foundation and toner bottles

Baby Products and Food

• Baby feeding bottles (PP, PPSU, 150-300ml)
• Infant formula scooping bottles
• தேன் மற்றும் பாகு கொள்கலன்கள் (LDPE)
• Small-volume special beverage containers
• Edible oil sample bottles
• தயிர் மற்றும் பால் பொருட்கள் பேக்கேஜிங்

Daily Chemical and Industrial

• Shampoo and conditioner bottles (HDPE/PP)
• Hand sanitizer and lotion dispensers
• Automotive fluid sample bottles
• Agricultural chemical concentrate bottles
• துப்புரவுப் பொருள் கொள்கலன்கள்
• Industrial reagent bottles with precise necks

1. Zero Flash Scrap

IBM produces no flash and no pinch-line scrap. EBM generates 20-40% of bottle weight as scrap per cycle. At 200 tons of PP per year, zero-scrap IBM saves 40-80 tons of resin annually. At 1,500 USD per ton, that is 60,000-120,000 USD in raw material savings per year from one machine alone.

2. No Deflashing Labor

EBM requires a secondary deflashing operation - either inline mechanical or manual - adding labor cost, a second machine footprint, and an additional quality failure point. IBM bottles from the EP80 come off the conveyor with zero post-processing required before filling or labeling, saving 1-3 operators per shift.

3. Short Dry Cycle Throughput

The EP80 achieves a 4 S dry cycle. With 14 cavities at 60ml, annual output at 6,000 hours run time exceeds 75.0 million bottles. This throughput concentration into a single compact machine reduces total asset investment per unit of capacity versus multi-machine EBM lines at equivalent output.

4. Quick Mold Changeover

The injection mold and blow mold on the EP80 can be changed in 2-4 hours by a trained two-person team. Recipe recall from the PLC removes setup time entirely for repeat jobs. Facilities running 8-15 SKUs on a single EP80 achieve mold changeover frequency of 2-4 per week with total changeover downtime below 10% of available production hours.

• ■செயல்திறன் மிக்க குழி மற்றும் கழுத்துத் தடுப்பு வடிவமைப்பு - injection mold cavities and neck blocks are independently adjustable, allowing preform tube body dimensions to be fine-tuned without replacing the entire mold set. Oil and water passages are purpose-designed for stable temperature distribution and easy disassembly.
• ■பிரீமியம் எஃகு தரங்கள் - injection mold bodies use 4Cr13 stainless steel or imported high-strength S136 alloy steel. S136 is a mirror-polish, corrosion-resistant steel with through-hardness to 52 HRC. Blow mold bodies can be manufactured in magnesium-aluminum alloy for superior thermal conductivity and reduced inertia mass on the rotary turret.
• ■உகந்த வெப்ப ரன்னர் மற்றும் முன்வடிவ வடிவமைப்பு - the hot runner manifold is engineered to minimize gram weight deviation across all cavities and to reduce wall thickness variation in the preform body. The mandrel design ensures uniform air delivery for consistent blow expansion and fast cooling.
• ■Precision neck thread and seal dimensions - bottle mouth inner and outer diameters, thread pitch and flange geometry are machined to drawing tolerance. Cap sealing rate is 100% across production-run samples.
• ■கழுத்து மற்றும் அடிப்பகுதியில் ஒளிப்பிழம்பு இல்லை. - the IBM process geometry eliminates parting-line flash at the bottle mouth and pinch-weld flash at the base. Bottles exit the EP80 with no trimming required at either end.
• ■Product consistency metrics - size, weight, parting line position and wall thickness are consistent across all cavities and across production batches, enabling pharmaceutical clients to validate production on a per-batch statistical basis without 100% inspection overhead.

Step 1: Calculate Preform Weight

Take the target bottle weight in grams (including the neck, body and base). Add 2-5% for process cushion. The EP80 injection weight of 466 g must be equal to or greater than (target preform weight x number of cavities). For example: a 5g preform at 8 cavities requires 40g shot weight, well within the 466 g capacity.

Step 2: Calculate Required Cavity Count

Target output (bottles/hour) divided by (3600 seconds / cycle time in seconds) gives required cavities. At a 4 S cycle and 10,000 bottles per hour target: 10,000 / (3600 / 4) = 12 cavities minimum. Cross-check against the cavity table above to confirm the EP80 can deliver this at your bottle volume.

Step 3: Verify Mould Platen Fit

The injection mould layout (cavity array footprint) must fit within the EP80 max platen size of 800x400 mm. Wide-bottle (diameter greater than 120mm) or tall-bottle (height greater than 220mm) applications exceed the EP80 mould envelope and require a larger model. Confirm your bottle OD and height before specifying cavity count.

Step 4: Material and Injection Pressure

PP requires higher injection pressure and melt temperature than LDPE. PC and PETG require even higher barrel temperatures and longer residence-time plasticization. The EP80 hydraulic system pressure of 14 MPa and motor of 18.5+18.5 KW supports the injection forces needed for PP and engineering grade materials at the rated injection weight. Confirm your resin specification with the EVER POWER application team before ordering.

Mould Design and Manufacture

EVER POWER engineers develop injection and blow mold sets from customer bottle drawings or 3D files. Multi-cavity hot runner molds in S136 or 4Cr13 steel. Prototype single-cavity molds for container validation before committing to high-cavity production tooling. T0 mold trials conducted at the factory before shipment.

Auxiliary Equipment Integration

The EVER POWER turnkey line includes: screw air compressor, air tank and air dryer, mold temperature controller, industrial chiller, auto loader, conveyor belt, screen printing and labeling system, washing and drying line, and automatic filling and capping machines. All auxiliary equipment is specified and pre-integrated to match the EP80 output rate.

Downstream Quality Systems

Optional inline bottle visual inspection machine (machine vision system for flash, deformation and contamination detection), automatic leak tester, automatic packing machine, and carton erector. For pharmaceutical lines, 100% inline leak testing and vision inspection are available as integrated modules matched to the EP80 conveyor output speed.

GMP and Cleanroom Configuration

For pharmaceutical clients requiring GMP-grade production, EVER POWER offers machine customization including: closed-system lubrication to prevent product zone contamination, stainless steel safety enclosures, HEPA-filtered machine enclosure for Class 100,000 cleanroom compatibility, and documentation support for equipment qualification (IQ/OQ/PQ) protocols.

CNC Machining of Critical Components

Machine bed, clamping platens, and all precision surfaces are CNC-machined in single setups to guarantee geometric accuracy. Platen parallelism is verified by laser measurement to 0.02mm. Tie-bar bores are honed to H7 tolerance for interference-free bearing fit.

Tie-Bar Induction Hardening

Tie-bars undergo high-frequency induction hardening to surface hardness of 52-58 HRC followed by precision grinding. This surface treatment provides wear resistance against the repeated sliding contact of clamping platens over millions of cycles without galling or fretting.

Hydraulic Circuit Cleanliness

All hydraulic circuits are flushed, pressure-tested and particle-count verified before assembly. Hydraulic oil cleanliness is maintained at ISO 4406 Class 17/15/12 as a minimum. Proportional and servo valve contamination sensitivity requires this level of cleanliness to prevent valve spool sticking and control drift.

72-Hour Factory Run-In Test

Every EP80 undergoes a minimum 72-hour continuous loaded run test at the factory before shipment. During this period, production output samples are measured for weight consistency, wall thickness uniformity, and dimensional accuracy. Any parameter outside specification triggers a hold and corrective action before the machine is cleared for delivery.

CE Safety Compliance

The EP80 is CE-marked in compliance with EU Machinery Directive requirements. Safety features include: interlocked safety doors with hydraulic circuit interrupt, light curtain protection at the operator access zone, emergency stop at all operator positions, and two-hand operator control for manual mold setting. CE documentation is provided with every machine.

நிறுவுதல் மற்றும் செயல்பாட்டுக்குக் கொண்டுவருதல்

EVER POWER senior engineers are responsible for installation, commissioning and acceptance testing. The engineer remains on site until the machine achieves stable production state and all operators are trained on machine operation, mold change and routine maintenance. Acceptance criteria are agreed before shipment and documented in the commissioning report.

Preventive Maintenance Program

EVER POWER provides a scheduled maintenance reminder service for all machines in service. The maintenance calendar covers daily, weekly, monthly and annual tasks. Proactive maintenance prevents unplanned breakdowns and reduces the need for expensive emergency part shipments. Customers following the preventive maintenance schedule consistently report machine availability above 95%.

24x7 சேவை ஹாட்லைன்

The EVER POWER service hotline is available 24 hours a day, 7 days a week. For urgent production breakdowns, call or message the service line and a qualified engineer will respond within 2 hours to diagnose the problem remotely. If on-site service is required, EVER POWER dispatches a technician with the minimum response time available for your location.

Spare Parts Inventory

EVER POWER maintains a comprehensive spare parts inventory for all EP80 components including hydraulic seals, proportional valve cartridges, heating bands, temperature sensors, drive belts and electrical components. Parts can be shipped globally within 48 hours for items in stock. Critical fast-wear items are available for customer-held local inventory based on EVER POWER recommendations.

Technical Training Programs

Beyond the standard installation training, EVER POWER offers dedicated training modules: machine operation, mold process optimization, mold change and setup, hydraulic system maintenance, and process troubleshooting for specific materials such as PP, LDPE and PCTG. Training can be conducted at the EVER POWER factory or at the customer facility.