Chapter VII — Injection Mould for Preform

§VII-1. Statements

Thank you for purchasing the PET Preform mould of EKOU Brand. Before installing your injection preform mould, please read this
operating instruction carefully and keep it for future reference.

We suggest that the installation and applications should be operated by experienced technicians to avoid unnecessary loses by
incorrect operation.

In case of any problem, please contact with our agent or us. Our technicians will reply you with tech support within 8 hours.

Our contact information: Hot line: +86-574-87138300

[email protected]

Your mould no. is

For after service, please inform us THIS MOULD NO.

Mark explanation

Attention! This mark indicates that more attention is necessary.

©Copyright 1998-2010, EKOU® Industries Co., Ltd. VII-1

Last updated on May 18, 2010.
 Chapter VII — Injection Mould for Preform

1. DRAWING OF THE PREFORM

The preform drawing is designed according to your bottle. We have sent the samples to you for your confirmation after we test the
mould.

2. CHARACTERISTICS OF THE MOULDS

2.1. General
The preform mould you purchased is the V4.0 structure, 4cav. 108gram.

The major Characteristics of the moulds are as follows:

(1) Knock-down cooling water pipe in cores leads to convenience for cleaning the cooling water pipe in cores.
(2) Pendular design of neck ring increases the using life of screw thread.
(3) Cavities which are mounted into the plate avoid damage of cavities by over extrusion.
(4) Good hot runner minimizes the pressure loss.
(5) Standard parts make each part can be exchanged mutually.
(6) Good insulation between nozzle and mould body decrease the heat loss.
(7) Least plug/socket for cooling water shortens mould's assembly duration.
(8) The mould is designed without off-center adjustment system to increase the precision.
(9) In the valve gate hot runner system, each nozzle has its own temperature controller;

2.2. Specifications:

1) The weight and dimension of the moulds Dimension (L×W×H)

2) Technical date
Voltage
Total power of the heating band and the heating sticks 12KW
Cooling water The temperature should be 10
℃ lower than environmental temperature or within 10 ℃
~15℃. Water flow rate: 10m³/h
Air 8kgf/cm³

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 Chapter VII — Injection Mould for Preform

3. Mould Assembly Drawing

Mould assembly drawing is simply drawn. Some parts are not on the drawing. Please refer to the practicality.

©Copyright 1998-2010, EKOU® Industries Co., Ltd. VII-3

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 Chapter VII — Injection Mould for Preform

4. Installation

Before hoisting, check whether the cranes can bear the weight of the moulds.
4.1. The Inspections of Moulds
1) Take out the moulds from wooden box; wipe the moulds’ surface with the cotton cloth.
2) Check the screws of the moulds. If loose, tighten them.
4.2. Installation of the Moulds
The installation must be done by experienced workers. Here is the brief introduction of the process of the installation. Hang the moulds
between the tie rods of the injection molding machine. Regulate the locating ring of the mould to the locating hole of the injection molding
machine. Shut the moving plate slowly. Press the cylinder plate and fix the core plate. Then slowly and slightly start the moving moulds
3~5times. Make sure the procedure of the start is stable and loose and without blocking. Finally fix the core plate; the installation of the
moulds is finished as Fig6-1 shows.

4.3. Installation of the Auxiliary Components

After the mould fixed on the machine, please take out all the auxiliary components and the spare parts from the wooden box. The
auxiliary components include the temperature controllers, the air cleaner, the Electromagnetic valves and the plastic pipes.

4.3.1. Pneumatic Components

Pneumatic components include the air cleaner, the Electromagnetic valve and the plastic pipes of dia.12mm. Join these parts as Fig7-1
shows and regulate the air cleaner as 8kgf/cm².

Remark: See Fig7-1, you can adjust air pressure in G.

4.3.2. Cooling Water

Requirements for cooling water: The temperature of the cooling water should be 10℃ lower than the environmental temperature or within
10℃~15. The water flow rate should be 10m³/h. Fig.7-2 indicates the quick couplings of the cooling water, IN shows water inlet; OUT shows
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 Chapter VII — Injection Mould for Preform
water outlet.

4.3.3. Connection of the Temperature Controller and Mould

The temperature controllers and the moulds are connected as Fig.7-3 shows.

4.4. Notice
1).Please check if the machine is fit for the preform mould.
2).Please if the mould is clean and fixed well.
3).Please check if the ejection bar fixed tightly.
4). Please check the nozzle and injection gate.
5). Please check the screw and make sure it is fixed tightly.
6). Please check if guide pin, guide bushing, slide etc. are working well.
7). Please make sure the cooling tower and the connector of cooling pipe are fixed tightly.
8). Run the machine smoothly and slowly to check every part are working well.
9). Check if the neck ring, core and cavity are clean enough. If not, please clean them up.
10). Please use the clean water supply.

©Copyright 1998-2010, EKOU® Industries Co., Ltd. VII-5

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 Chapter VII — Injection Mould for Preform
5. Mould Testing and Operation
5.1. Mould Testing
z Heat the injection molding machine with the cooling water switch open.
z When the temperature of barrel reaches 200℃, begin to cool water and heat the manifold plate (The temperature of the manifold plate
should be about 265℃).
z When the manifold plate is heated to 200℃, begin to heat the nozzle tip. (The voltage of the heating band should be 110V~130V). Begin
to supply the compressed air.
z When the machine and the mould reach the setting temperature, stop the air supply, inject the material in barrel until the materials are
injected out and transparent without bubbles. Then supply the air again;
z Check whether the valve stem of each cavity can open and close. Set up the injection delay time 0.3~0.5secs,
injection manually without starting the motor. Meanwhile use a copper stick (dia. <4mm) to check if the valve stem can move.
z Begin the semi-automatic production.

Producing the preform repeatedly, until to meet your requests, e.g. totally transparent, without any bubbles, and no unmelted materials etc.

When you test the mould, the preform should be ejected by Length Both.
5.2. Mould Operation
After finish testing of the mould,
z Open the mould as Fig.9-1 shows;
z The extra ejection pin is installed on the machine’s ejection pin to make it longer and makes sure the preform can be lifted out. As Fig.9-
2 shows;
z Close the preform mould befittingly, and dismantle the screw in Length both, see Fig.9-3/1; then separate the length both from ejector
plate, and put the Length both into Cavity plate as Fig.9-4/3 shows.
z Please connect the ejector plate with extra ejection pin. Finish installation as Fig.9-4 shows, and then produce full-automatically.

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 Chapter VII — Injection Mould for Preform

6. Maintenance and Preservation of the Mould

Carrying on effective maintenance and preservation can guarantee that the service life of the moulds is longer.
6.1. Keep in Mind Firmly
1) Materials should not stay too long time in the barrel and the hot runner, or it will be degraded and burnt, and owing to
the long time, the products will be polluted and hot runner will be destroyed.
z The equipment may stop working for more than 15minutes, the temperature of the manifold plate and nozzle tip must be
reduced;
z The equipment may stop working for more than 40minutes; the temperature controller must be shut down.

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 Chapter VII — Injection Mould for Preform

2) The mould must keep the open water at the high temperature, or the temperature that too high deform the manifold plate so as to
leak the material.
z When you start the machine, make sure that the water flow is normal;
z When you shut down the machine, make sure that the temperature should be dropped to at least under 80 ℃. Then you
can stop supplying the water.

6.2. The Maintenance of the Moulds

1) The mould’s screw should be often checked, if loose, tighten them.

Every shift must check the screws of neck ring (see Fig.11-1/7) loose or not. If loose, the worker must tighten them. If the neck ring
and Cavity taper were polluted, please clear it in time.
2) It should take 30minutes to clear up the moulds every 7 days. Use the compressed air to blow the cooling lines to remove the pollutants
and blockages. 2) Keep the neck ring, cavity, core clean. Lubricate each moving part, esp. in summers;
3) With full-automatic production, you must use injection machine with mould protects function;
4) When the mould is closed, no material is allowed to exist between the core and the cavity, or it will damage or even destroy the moulds;
5) Use the clamp force as small as possible to make the mould life longer;
6) Before production, remove the remained material in barrel until the material is transparent and without bubbles;
7) Only the clean water can be adopted for cooling mould, if using the groundwater, please pay attention to salt content;
8) If the preform are glued on the core and can not be lifted out by ejector plate, you should use pliers to rotate the preform and pull it
outward or use the copper stick to break the preform;
9) check the auxiliary system regularly;
z The Voltmeter and temperature meter in Temperature Controller;
z The heating stick and the heating band;
z Check the cylinder of the mould leak or not;
z The air cleaner and the electromagnetic valve.

10) If you need repair of the hot runner, please contact with our company;

If you repair the hot runner system by yourself, we will send spare parts to you and instruct you how to repair it;
If you can’t repair the hot runner system, our company will send our technicians to repair it for you.

6.3. The Preservation of the Mould

1) After the mould is pulled down from machine, clear it overall, it contains the internal and external mould parts (including the core,
the cavity and the surfaces of the moulds. etc). They need antirust;
2) The water in cooling channel must blow off by compressed air, preventing the cooling channel from getting rusty and blocked;
3) The mould should be preserved under dry condition, kept clean and placed on the wooden cushion.

7. Sketch Drawing For Parts Changing

Please read the mould assembly drawing carefully before repair the mould.
Any part is damaged within the guarantee period (within 1 year), please send photos.

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 Chapter VII — Injection Mould for Preform

After confirmation, we will send the parts to you within one week.

7.1. The Replacing of the Core and Core Seat, the Neck Ring
The core and core seat，the neck ring can be replaced on the machine. Open the mould manually as Fig.9-3 shows. And replace the
damaged parts. When replacing the core and core seat, stop supplying the cooling water of the core plate and make sure it do not damage the
copper water pipes in core. See Fig.12-1.

7.2. The Replacing of the Cavity and the Seal

Unload the mould from the machine. Open the mould put the mould on the wooden cushion. Separate the cavity plate. Finally replace the
damaged cavity or the seal. See Fig.12-2

©Copyright 1998-2010, EKOU® Industries Co., Ltd. VII-9

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 Chapter VII — Injection Mould for Preform

When replace the cavity, pay attention to the relation between the cooling water channel of the cavity and the cooling water channel
of its plate.

7.3. The Replacing of the Nozzle Tip Insulator, Nozzle tip and Heating Band
The nozzle tip insulator, nozzle tip and heating band can be replaced on the machine. Open the mould manually. Dismantle the screws
(Fig.12-2/1). Close the mould, then open the mould slowly so as to remove the cavity plate and moving plate together, finish see Fig.12-3 show.
Then replace the nozzle tip insulator, nozzle tip and heating band.

Operate nozzle tip and insulated strap as Fig.12-4 shows. Then put them in the nozzle housing. Notice that the height of the nozzle
tip should be the same with others.

7.4. The Replacing of the Heating Stick and the Thermocouple

1) It’s easy to explain how to replace the thermocouple;
2) The replacing of the heating stick. You should use the pliers or a hammer to pull out the heating stick.

7.5. The Replacing of the Valve Stem, the Seal and the Cylinder
Heat the manifold plate and nozzle tip to melt the plastic, and then open the cylinder. Take out the piston as Fig.12-5 shows and
meanwhile, supply to the mould in order to help take out the piston. Finally replace of the valve stem, the seal and the cylinder.

8. The PET Process Troubleshooting Guide

Here, we mainly introduce how to eliminate some trouble. If the solution as follows can’t find, please contact us by
[email protected], we will reply you within several hours.

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 Chapter VII — Injection Mould for Preform
DESCRIPTION POSSIBLE CAUSES SOLUTIONS
The distance of ejection is not enough. Adjust the distance of ejection.
The pressure of ejection is low. Increase the pressure of ejection.
The preform can’t be ejected from the
The screw of neck ring (see Fig.11-1/7)
mould automatically. Tighten the screws of neck ring.
are too loose.
The temperature of barrel is not enough. Appropriately increase the temperature of barrel.
1) Appropriately increase the temperature of
The temperature of hot runner system is manifold plate;
The lack of perform neck. not enough. 2) Appropriately increase the temperature of
nozzle tip.
The injection weight of machine is not 1) Use big machine;
enough. 2) Reduce the cavity of mould to production.
1) Check water cooling system, including
Buckling caused by insufficient mould pressure, flow and temperature;
cooling. 2) Check the cooling channe for blockage or
contamination;
3) Increase preform cooling time.
1) Appropriately decrease the temperature of
The preform is buttoned up in the Too high temperature of the melting
the machine;
core or the cavity. brings on excessive shrinkage or
2) Appropriately decrease the mould
performs temperature.
temperature.
Insufficient hold to compensate for 1) Increase hold pressure;
shrinkage and proper heat transfer. 2) Increase holds time.
Injection pressure is too high. Decrease the injection pressure.
1) Raise the temperature of the cooling
Moisture congeals in the core of the water, preventing the air around from congealing;
mould. 2) Regulate the dehumidification system,
preventing the air around from congealing.

1) Reduce the temperature of the nozzle tip;

2) Reduce the temperature of manifold plate;
3) Reduce the temperature of the machine;
4) Clean the barrel until the fresh material
is injected out.
Black particles caused by degraded melt
5) Check whether the material is degraded
The black particles exist in preform wall in dryer;
6) Check whether the nozzle tip is destroyed;
7) Reduce screw speed, back pressure or
injection rate.

The foreign debris is injected into the Check whether there is the foreign debris in the
preform. material.
There are bubbles in the wall of the Check the parameters of the
The materials are not dried enough.
preform. dryer, for example the drying
temperature, time etc.
1) Lower the temperature of the nozzle tip;
2) Low the temperature of the manifold
The burnt traces of the black and brown
plate;
at the bottom of the preform and the The degraded melting substances cause
3) Lower the temperature of the machine;
wall. the burnt traces.
4) Minimize the starting time;
5) Check whether the nozzle tip has
damaged.

©Copyright 1998-2010, EKOU® Industries Co., Ltd. VII-11

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 Chapter VII — Injection Mould for Preform

1) Decrease hold pressure;

Preform sticking in the mould cavity due
2) Increase injection transition position;
to over hold.
3) Decrease shotsize.
1) Increase cooling time;
The ripple form of the perform at 2) Check the cooling system, including
Preform sticking in the mould cavity due
bottom pressure, flow and temperature;
to insufficient shrinkage.
3) Check mould cooling channels for
contamination and blockage.
The nozzle tip is overheated to cause
Decrease the temperature of the nozzle tip.
the preform glued to the cavity.
1) Decrease injection shotsize;
Because the PET material are forced
2) Decrease holds pressure;
through the parting line.
3) Decrease injection pressure.
1) Decrease the temperature of the manifold
Because the low melt viscosity of the
plate;
materials causes the plastic to flow into
2) Decrease the temperature of the machine;
There are thin plastic protrusion the parting line.
3) Decrease injection raw.
between adjacent mold
component surfaces (i.e. neck ring/ Clamp force is not enough. Increase the clamp tonnage.
neck ring, neck ring/cavity, neck
ring/the locating ring of the core seat) 1) Check the screw of the neck ring (Fig.11-
1/7) whether loose;
Slight gap open at mould parting lines 2) Check the locating ring of the core seat,
and vents due to incorrect positioning of neck ring, cavity taper damaged or not;
neck rings. 3) Check whether the neck ring, the locating
ring of the core seat and cavity taper are polluted
and cause the mutual interference.

White crystalline formations The mould’s temperature of nozzle tip is

Increase the temperature of nozzle tip.
appearing in the preform gate area. too low.
1) Decrease the temperature of nozzle tip;
2) Check the cooling eater: Temperature,
The melting temperature of the nozzle
flow and pressure;
tip is too high or the gate is too hot.
3) Check whether the heating band touch
They cause a deep white haze
cavity;
(Especially in performs with thick wall
4) Reduce melt shear heat in nozzle tip
sections).
/gate passage by reducing injection fill rate;
5) Increase the cooling time.
The valve stems touches the gate too Keep valve stems open longer after hold (Preform
long cause heat lose. gate nub quality permitting).
1) Check mould nozzle tip and gate area for
Stress induced crystallinity due to melt
contamination or obstruction;
flow restriction.
2) Check to ensure valve stem is opening
properly.
The material hasn’t thoroughly dried. In
the course of the Plasticizing, it causes
Check whether the raw materials are thoroughly
A cloudy white appearance the materials hydrolyze, Causing the raw
dried.
spread uniformly throughout the preform material VI lost and the increase of the
body. speed of crystallizing.
The melting temperature is not enough. Increase the temperature of the machine.

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 Chapter VII — Injection Mould for Preform

1) Check the cooling system;

The shortage of the cooling causes 2) Check mould cooling channels for
crystallizes again. contamination and blockages;
3) Increase preform cooling time.

The gate is too cold to close thevalve

Increase the temperture of the nozzle
gates.

1) Increase the temperature of the manifold

plate;
2) Check the air pressure of valve stems;
There is a nub at the gate 3) Check the foreign materials at the nozzle
The valve stems can’t be normally tip and clear them;
closed. 4) Check whether the nozzle is damaged or
not. If it is, exchange a new one;
5) Check whether the seal of the
valve stem is damaged or not.
If it is, replace a new one

The moisture causes the material VI

The VI values descend. Check the material aridity.
loses.
1) Reduce the machine temperatures;
2) Reduce the screw speed and back
Excessive melting degradation causing a
pressure to reduce shear heat;
reduction in IV due to increased
3) Reduce the injection speed to reduce
molecular chain scission.
shear heat;
4) Increase the mould temperature.

The VI doesn’t meet the requests. Insure the VI values both before and after drying

©Copyright 1998-2010, EKOU® Industries Co., Ltd. VII-13

Last updated on May 18, 2010.