The packaging industry in our country, Iran, has made significant progress in recent years, and the need for advanced machinery to produce plastic bottles is felt more than ever. The PET Blow Molding machine is one of the most vital equipments in the production lines of beverages, mineral water, oil and detergents. Buying this device is only the first step, and the steps of installing and setting up the pet inflator device are equally important. The correct implementation of these steps has a direct impact on production efficiency, the quality of the final product, and the useful life of the machinery. In this article, we will do a detailed and step-by-step review of how to install, configure and set up these devices in Iran's climatic and industrial conditions.
The importance of correct installation of the pet inflator device
Installing and setting up the inflatable pet device is a specialized process that requires technical knowledge and practical experience. A non-standard installation can lead to problems such as air pressure fluctuations, non-coordination of molds, increased production waste and even serious damage to the mechanical parts of the device. In Iran's highly competitive industry, stopping production means losing the market; So ensuring proper installation in the early days will ensure peace of mind for the manufacturer in the years to come. In addition, compliance with standard principles in installation also results in personnel safety and energy efficiency.
Environmental prerequisites for device installation
Before entering the pet inflator into the production hall, environmental conditions must be measured and provided. These prerequisites include the following:
1. The dimensions and floor of the production hall
Sufficient space is necessary for the movement of the operator, repairs and maintenance of spare parts. In addition to the dimensions of the device itself, space for the air compressor, filling device and conveyor belts should be considered. The floor of the hall must be smooth, level and have high pressure resistance so that the heavy weight of the machine and the vibrations caused by the operation do not cause the floor to crack. It is suggested that the concrete floor be implemented with proper reinforcement and epoxy coating to comply with the health of the environment.
2. Air conditioning and ambient temperature
The pet inflator has heating and electrical systems that generate heat. On the other hand, air compressors are also heat producing. In many cities of Iran, especially in summer, the ambient temperature can reach above 40 degrees Celsius. This heat causes premature failure of electronic components and air pressure drop. Therefore, it is necessary to install industrial ventilation systems, air conditioners, and suction fans to remove hot air. The ideal temperature for the operation of these devices is between 20 and 30 degrees Celsius.
3. Relative humidity of the air
High humidity can damage electronic components and electrical panels and cause corrosion of pneumatic connections. In the northern and southern regions of Iran, which have high humidity, it is very important to use humidifiers or air controllers.
Steps to prepare infrastructure facilities
After preparing the space, it is time for the facilities. Pet blower needs electricity, air and water to work.
Industrial electricity supply
Most fully automatic and semi-automatic pet inflator devices require three-phase electricity with a voltage of 380 volts and a frequency of 50 Hz. The power consumption varies depending on the capacity of the device (for example, between 15 and 60 kW). The wiring should be done with copper cables with a suitable standard and a sufficient cross-section diameter so that the voltage drop does not occur due to the high current of the servo motors and heaters. A genuine automatic switch and suitable protection fuses must be used. Earthing the system is also critical to prevent electric shock and damage to the PLC.
Compressed air system (Air Compressor)
The beating heart of the inflation process is high quality compressed air. Two types of air pressure are needed to operate the PET inflator: high pressure air (high pressure) about 30 to 40 times to inflate the bottle, and low pressure air (low pressure) about 8 to 10 times to perform pneumatic movements. Piston or screw compressors should be selected with a capacity suitable for the device. It is necessary to have an air tank to stabilize the pressure and an air dryer to separate the moisture from the compressed air. Moisture in the air can cause cracks in the body of the bottle and damage to the valves.
Chiller water supply
Pat blowing process requires cooling of molds. Hot molds cause the plastic not to form and lose its shape. The industrial chiller device circulates cold water in the mold circuit. The temperature of the water entering the mold should be set between 8 and 12 degrees Celsius. Water piping must be made of high-quality five-layer pipes, and leakage in connections is not acceptable in any way.
The physical steps of installing the inflatable pet device
Now that the infrastructure is ready, it is time to enter the device and install it.
Moving and placing in place
Pet inflator is usually shipped in strong wooden packaging. After unloading in the hall, the device should be placed on the intended location using a suitable crane or forklift. A very important point at this stage is to level the device. The device must be completely leveled in both longitudinal and transverse directions using accurate levels (Bubble Level). The lack of alignment of the device causes strong vibration at high speeds, wear of mechanical parts and instability in the inflation process.
Installation connections
After leveling, electrical, air and water connections are made. The connection of the high and low pressure air ports must be done carefully using special high pressure hoses. The inlet and outlet water connections to the chiller and molds must be tightly closed. In the electrical phase, the phases must be checked so that the rotation direction of the motors (for example, the hydraulic oil pump or the cooling fan) is correct.
Initial setup and parameter settings
After completing the physical installation, it is time to turn on the device and set the parameters. This step should be done under the supervision of technical experts.
Turn on and test without load (Dry Run)
First, the device is turned on without a preform and without a mold to check the movement of the mechanisms. At this stage, the hydraulic oil is heated and possible leaks are checked. The movement of axles, the performance of pneumatic valves and safety systems (Emergency Stop) are tested.
Oven temperature settings
Setting the temperature of the infrared lamps in the oven is one of the most sensitive parts of setting up the pet blower. The temperature should be such that the preform is properly softened but not melted. This setting is different depending on the type of PET and the weight of the preform. Usually, the temperature starts from the neck of the bottle, which should not be heated, and increases towards the body. The use of accurate temperature sensors and the adjustment of the power percentage of the lamps are done in the HMI panel.
Pressure settings and inflation time
In the control panel, the parameters of the initial blowing time (Pre-blow) and final blowing (Final Blow) are set. Also, the compressed air pressure should be kept within the standard range. Accurate timing of opening and closing of the molds is very critical to prevent the parts from colliding and the bottle to come out correctly.
Production test and sampling
At this stage, the preforms enter the machine and several rounds of production are performed. Prototypes are checked for appearance, transparency, wall thickness and absence of air bubbles. If there is a problem, the temperature and pressure settings are modified to achieve the desired quality.
Personnel training and work safety
Setting up the pet inflator is incomplete without training the personnel. Operators should be familiar with how to work with the touch panel, simple troubleshooting and safety principles.
Safety tips for working with the device
- Always wear work clothes, gloves and safety glasses.
- Never touch the moving parts or the mold while the machine is working.
- If you notice any unusual noise or vibration, turn off the machine and notify the technical unit immediately.
- Avoid tampering with wiring and safety valves.
After-sales service and support in Iran
Due to the sanctions and restrictions on the import of parts, it is very important to choose a company that has a strong after-sales service inside Iran. Companies like Azer Pet, with their expert technical team and available spare parts, can assist manufacturers in the stages of installation, start-up and repairs. Quick access to consumable parts such as valves, cylinders and electronic components minimizes production stoppages.
Common troubleshooting in the early days of startup
Even with the best installation, small problems can occur. Some of these items include:
conclusion
Installing and setting up the inflatable pet device is a complex process that requires compliance with technical and safety standards. By complying with environmental prerequisites, providing electricity, air and water infrastructure, and performing detailed adjustments by experienced experts, you can maximize your production efficiency. Investing in proper installation and personnel training will greatly reduce repair costs and production downtime in the future.
To get more information about buying high-quality pet inflator devices and receiving professional installation and commissioning services throughout Iran, we suggest you to visit Azarpet website. The specialists of this collection are ready to answer your questions and provide the best industrial solutions.
