Beschreibung
Einstufen-Blasformmaschine HGY200-V4-B: Die AOKI-250-kompatible Hochleistungs-ISBM-Lösung
Engineered by Ever-power | 4-Station Precision | 300KN Injection Clamping | 250KN Blow Clamping
Engineering Overview: Breaking the Mold Compatibility Barrier
In my two decades of optimizing polymer processing lines, the most common bottleneck I’ve encountered isn’t cycle time—it’s tooling flexibility. Many manufacturers are locked into expensive ecosystems. The HGY200-V4-B is Ever-power’s strategic answer to this challenge. This is a heavy-duty, 4-station Ein-Schritt-Blasformmaschine specifically engineered to be fully compatible with Japanese AOKI-250 molds.
This machine is a powerhouse. Unlike standard 4-station units, the V4-B variant is reinforced to handle massive cavitation (up to 12 cavities for small vials) and heavy-weight containers. It boasts a 300KN Injection Clamping Force and an upgraded 250KN Blow Clamping Force (higher than the standard V4’s 200KN). This additional clamping power allows for the production of wide-mouth jars and thick-walled cosmetic containers without parting line expansion or flash, even when using materials with high viscosity like PC or PCTG. It is the ultimate Ein-Schritt-PET-Flaschenmaschine for manufacturers seeking to expand capacity using their existing high-value Japanese tooling.
Figure 1: The Ever-power HGY200-V4-B (AOKI-250 Compatible Model)
1. Technische Standardkonfiguration
We do not compromise on kinetics or thermal control. The HGY200-V4-B integrates a “Who’s Who” of global engineering components to ensure it matches the reliability of the Japanese machines it is designed to complement.
| System / Komponente | Marke / Spezifikation |
|---|---|
| Servosystem | 3 sets of servo pump systems |
| Servomotorleistung | 49,2 kW (Inovance / WEICHI) |
| Steuerungssystem (SPS) | Inovance / MIRLE (High-speed logic processing) |
| Drehtellerrotation | Yaskawa Servo (Japan) oder WEICHI Servo + TSUNTIEN Reduzierstück (Taiwan) |
| Blasformstruktur | Hydraulischer Zylinder oder Doppelservomotor-Formdämpfungssystem mit Hochdruckkompensation |
| Hochdruckventil | Parker (USA) |
| Pneumatikzylinder | Airtak (Deutschland/Taiwanische Technologie) |
| Temperaturregelung | Integrated Control Box (High accuracy for consistent viscosity) |
| Hydraulische Steuerung | YUKEN (Taiwan) Druckregelventil |
| Schraubenheizung | Nano-far-infrared energy-saving heating ring (15KW) |
| Einspritzanlagensteuerung | Single cylinder control (Hydraulic or Servo Melt Motor options) |
| Formkompatibilität | Compatible with Japanese AOKI-250 mould |
| Gesamtleistung | 64.2 KW |
2. Machine Parameters: The Heavy-Duty Specification
The “B” in V4-B signifies enhanced capability. Note the increased shot weight (442g) and Blow Clamping Force (250KN) compared to standard models, designed for the rigors of AOKI tooling requirements.
| Parameter | Wert |
|---|---|
| Schraubendurchmesser | 50 mm (Standard) / Optionen: 40, 55, 60 mm |
| Theoretische Einspritzkapazität | 442g (High volume capacity) |
| Einspritzklemmkraft | 300 kN |
| Blasklemmkraft | 250 KN (Upgraded for heavy molds) |
| Oberer Formenhub | 600 mm |
| Unterer Formhub | 350 mm |
| Temperaturregulierender Kernschlag | 300 mm |
| Temperaturregulierender Zylinderhub | 350 mm |
| Auswurfschlag | 175 mm |
| Blow Core Stroke | 300 mm |
| Blasform-Schlaganfall | 75 + 75 mm |
| Öltankvolumen | 300 L |
| Maschinenabmessungen (L*B*H) | 4800 x 2000 x 3800 mm |
| Maschinengewicht | 13 Tonnen |
Production Capacity: Versatility from Jars to Vials
| Produktmenge (Kavitäten) | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 10 | 12 |
|---|---|---|---|---|---|---|---|---|---|---|
| Maximaler Flaschendurchmesser (mm) | 118 | 110 | 105 | 100 | 68 | 65 | 48 | 45 | 38 | 26 |
| Maximale Flaschenhöhe (mm) | 280 (Increased Height) | 150 | 100 | |||||||
| Halsdurchmesser (mm) | 90 | 90 | 90 | 65 | 38 | 32 | 26 | 25 | 23 | 15 |
| Maximales Flaschenvolumen (ml) | 2500 | 1500 | 900 | 750 | 350 | 200 | 100 | 50 | 30 | 20 |
| Maximales Flaschengewicht (g) | 150 | 65 | 45 | 35 | 30 | 28 | 25 | 20 | 15 | 10 |
4-Station Process Principle: The ISBM Advantage
Der ISBM Blasformmaschine maximizes quality by controlling the polymer’s thermal history. The HGY200-V4-B employs a 4-station rotary table layout, ensuring that the preform is conditioned to the exact optimal temperature before stretching.
1. Einspritzstation
PET/PCTG is injected into the cavity. The 300 kN Klemmkraft is critical here, allowing for high-pressure injection needed for precision necks and thin-wall preforms without flash.
2. Klimatisierungsstation
The “Heart” of the 4-station process. The preform is thermally equalized. We can heat the core or cool the skin, creating the perfect profile for difficult shapes like oval bottles or off-center necks.
3. Dehnen & Blasen
A stretch rod extends the preform axially, while air expands it radially. The upgraded 250KN Blow Clamping Force ensures the mold stays shut under high pressure, eliminating parting lines.
4. Auswurf
The finished container is stripped from the lip mold. The HGY200-V4-B features an extended take-out stroke (175mm) to accommodate taller bottles (up to 280mm).
Why Choose the HGY200-V4-B? Core Advantages
- ✓
AOKI-250 Mold Compatibility: This is the defining feature. We have engineered the platen dimensions, tie-bar spacing, and stroke lengths to perfectly match the AOKI-250. You can run your legacy molds immediately. - ✓
Superior Clamping Power: With 300KN Injection and 250KN Blow clamping, this machine outperforms standard market alternatives, ensuring flash-free production of heavy-weight jars. - ✓
Energy Dynamics: We use Nano-far-infrared heating rings (15KW) which penetrate the barrel deeper and faster than standard ceramic heaters, saving ~30% on heating costs. - ✓
Versatility: From 12-cavity eye drop vials to 4-cavity 750ml sport bottles, the machine adapts. The increased bottle height allowance (280mm) opens up new market segments.
Strategische Analyse: Ein-Schritt- vs. Zwei-Schritt-Systeme
| Vergleichsdimension | Immer-Power-Ein-Schritt-ISBM | Traditionelles Zweistufenverfahren (Aufwärmen) |
|---|---|---|
| Prozessablauf | Harz -> Flasche (integriert) | Harz -> Vorform -> Abkühlen -> Wiedererwärmen -> Abfüllen |
| Energieeffizienz | Hoch (Nutzt latente Injektionswärme) | Niedrig (Energieverlust durch Wiedererwärmung der Vorformlinge) |
| Oberflächenqualität | Einwandfrei (Keine Abnutzungsspuren/Kratzer) | Risiko von Transportkratzern an den Vorformlingen |
| Anwendbare Materialien | PET, PETG, PC, Tritan, PPSU, PP | Hauptsächlich beschränkt auf PET/PP |
| Platzbedarf | Kompakt (Ein Gerät) | Groß (Benötigt Einspritzeinheit + Blasanlage + Lager) |
| Scrap Rate | Low (Closed loop feedback) | Higher (Preform defects + Blow defects) |
Branchenanwendungen
Hochwertige Kosmetik
Der Einstufiges Spritzblasformen process is the only way to achieve glass-like clarity for thick-walled cosmetic jars. The HGY200-V4-B’s 250KN blow clamp eliminates the “parting line visibility” issue common in lower-end machines.
Pharmazeutika
From 20ml eye drop vials (12 cavities) to 500ml syrup bottles. The touchless “pellet-to-bottle” process guarantees ISO-standard hygiene levels.
Tritan™ & Sports Bottles
Tritan and PC require precise temperature control to avoid hazing. Our 4-station conditioning allows for exact thermal profiling to maintain the clarity of these expensive resins.
Power System Selection Summary: Ever-power vs. AOKI/ASB
We respect the Japanese pioneers. However, Ever-power offers a compelling alternative: 95% of the performance at 60% of the investment cost.
Die Dauerleistungsgarantie: The HGY200-V4-B isn’t a “cheap copy.” It uses the same Yaskawa servos, Parker valves, and NSK screws. We simply optimize the manufacturing overhead.
ROI Case: Cosmetic Jar Manufacturer
Umstellung vom Kauf von Vorformlingen auf eine Eigenfertigung Einstufen-Blasformanlage aufstellen:
- Tooling Savings: If you already own AOKI-250 molds, you save $30,000-$50,000 immediately by not needing new molds.
- Materialeinsparungen: Die Pelletkosten sind um ca. 251 TP3T niedriger als die Vorformkosten.
- Amortisationszeitraum: With existing molds, the ROI is often achieved in under 10 months.
[Globale] Resilienz gegenüber extremen Bedingungen
For our clients in varying climates, the HGY200-V4-B is equipped with an advanced hydraulic oil cooling loop. Whether you are operating in the humid summers of Southeast Asia or the freezing winters of Russia, the system maintains a stable oil temperature of 40-50°C, ensuring consistent clamp pressure and cycle times.
Einhaltung: CE-zertifiziert, auf Anfrage konform mit den UL-Elektronormen.
FAQ für Ingenieure
Can I really use my AOKI-250 molds without modification?
Yes. The platen layout, tie-bar spacing, and daylight opening are engineered to match. In some rare cases with very old molds, minor adaptor plates might be needed, but 99% of AOKI-250 molds fit directly.
What is the max shot weight?
The machine boasts a theoretical injection capacity of 442g, which is significantly higher than many standard competitors, allowing for very thick-walled luxury containers.
Bieten Sie auch die Installation an?
Ja, wir entsenden Ingenieure weltweit zur Installation, Inbetriebnahme und Schulung Ihrer Mitarbeiter.
Globale Fallstudien: Feldnotizen von Ingenieuren
Thailand: Retrofit Success
“We had 5 AOKI machines and needed to expand. The HGY200-V4-B ran our existing molds perfectly.” – Plant Manager, Bangkok
Brazil: Heavy Jars
“The 250KN blow clamp solved our flashing issue on the 200g cream jars.” – Tech Director, São Paulo
Germany: Energy Saving
“The servo system reduced our electricity bill by 35% compared to our older hydraulic units.” – Ops Lead, Hamburg
Vietnam: High Volume
“Running 12 cavities for eye drops, stable cycle times 24/7.” – Production Head, Hanoi
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