Description
Precision 3-Station IBM with Zero Scrap, Injection-Molded Neck Finish, GMP-Compliant Pharmaceutical Grade Output
Plant Scaling Expert Perspective: The ZQ135 High-Volume Platform
Scaling up pharmaceutical and premium cosmetic packaging requires machinery that does not compromise on micro-tolerances when operating at maximum capacity. The Ever-power ZQ135 is our most formidable IBM machine (Injection Blow Molding). Featuring a colossal 18-Ton frame and a 1300x500mm platen, it is engineered to drive up to 30 cavities continuously. Operating on a relentless 3-station synchronous cycle (Injection – Blow – Stripping), this system guarantees exceptional yield while entirely negating the contamination risks inherent in extrusion lines.
The core philosophy of the ZQ135 is pure non-stretch formation. Unlike ISBM processes that induce axial stress, the ZQ135 forms the preform via high-pressure injection and subsequently shapes it using pure radial pneumatic expansion. This dictates absolutely flawless SPI-standard neck threads, a seamless and structurally superior base, and a wall thickness deviation locked at ≤±1%. When processing high-density polyolefins like HDPE and PP, this method ensures absolute seal integrity for induction-lined child-resistant caps.
IBM Process Decision Guide: Why Master the Non-Stretch Process?
As a seasoned injection blow molding machine manufacturer, we urge procurement teams to align machinery strictly with resin behavior. If your production demands <500ml vessels, thick-walled HDPE/PP/PS, and pharmaceutical-grade cleanroom compliance, pure IBM is the only scientifically correct pathway.
| Critical Attribute | Ever-power IBM (ZQ135) | Extrusion Blow (EBM) | Injection Stretch (ISBM) |
|---|---|---|---|
| Scrap Generation | Zero Scrap. No deflashing required. | 20-40% flash; mandates dusty regrind lines. | Zero Scrap. |
| Neck Finish Integrity | Injection-Molded. Absolute SPI precision. | Calibrated blow pin; susceptible to ovality. | Injection-Molded. |
| Forming Kinematics | Pure Radial Expansion ONLY. No elongation stress. | Continuous extrusion drop + mold pinch. | Requires mechanical axial stretch rod. |
| Base Architecture | Seamless, high-impact convex base. | Pinch-off weld seam (structural weak point). | Injection gate vestige remains. |
| Target Polymers | HDPE, LDPE, PP, PS, ABS. | PE, PVC, PP. | Exclusively engineered for PET. |
ZQ135 Core Technical Specifications
Built upon a heavy-duty full European-style structure, the ZQ135 provides a clamping force 20%-30% greater than standard machinery. A 37+37 KW dual hydraulic system ensures zero pressure variance when injecting the massive 650g melt shot across 30 cavities.
| System Category | ITEM | Unit | ZQ135 Parameters |
|---|---|---|---|
| Injection System | Screw Diameter | mm | 70 |
| Screw L/D | % | 22:1 | |
| Injection weight | g | 650 | |
| Heating power | KW | 30 | |
| Number of barrel zone | – | 6+N | |
| Injection stroke | mm | 200 | |
| Clamping System | Clamping force of injection | KN | 1350 |
| Opening stroke for injection | mm | 140 | |
| Clamping force of blowing | KN | 200 | |
| Opening stroke for blowing | mm | 140 | |
| Lifting height of rotary table | mm | 70 | |
| Mould Specifications | Max. Platen size (LxW) | mm | 1300×500 |
| Mold thickness | mm | 280 | |
| Dia. of bottle | mm | 120 | |
| Bottle height | mm | 220 | |
| Suitable bottle height (Volume) | mm | 1-2000 | |
| Stripping stroke | mm | 280 | |
| Hydraulic System | Hydraulic Pressure | MPa | 14 |
| Motor power | KW | 37+37 | |
| Dry cycle | S | 4 | |
| Total Power | KW | 95 | |
| Operating power | % | 52-70 | |
| Utilities & Dimensions | Min. Air pressure of compressed air | MPa | 0.7- 1.2 |
| Compressed air capacity | M³/min | 0.7 | |
| Water flowage | M³/h | 4 | |
| Cooling water pressure | MPa | 0.3-0.4 | |
| Dimension (Lx W x H) | M | 5.5x2x2.4 | |
| Net weight | Ton | 18 |
ZQ135 Mega-Cavitation Matrix
| Approx Volume | 10ml | 30ml | 60ml | 100ml | 250ml | 500ml | 1000ml |
| Max Cavitation | 30 | 26 | 22 | 18 | 14 | 10 | 8 |
Smart Manufacturing: Syncing 30 Cavities
Managing the kinetics of an 18-Ton frame with a 1300x500mm platen requires uncompromising mechanical logic. The ZQ135 achieves precision via two integrated intelligent structures:
- Standard High-Precision Angle Divider: This mechanical heart realizes the flawless synchronization of mold opening/closing and turret lifting. It eradicates the violent mechanical shudder common in inferior high-cavitation machines, ensuring that all 30 core rods align with micron-level precision during mold engagement.
- Energy-Efficient Booster Clamping: We eliminated wasted kinetic energy by decoupling the high-pressure mold lock from the rapid traverse stroke. The unique booster cylinder does not participate in the opening and closing action. It activates solely for the final 1350 KN lock, dropping hydraulic fluid displacement and yielding a proven 20%-30% energy consumption reduction.
✔ Injection Molded Neck = 100% Seal
Natives threads formed inside a high-pressure injection cavity. This completely eliminates the bore variations and ovality associated with extrusion blow pins, guaranteeing airtight FDA compliance.
✔ Zero Flash / No Trimming Required
True no scrap blow molding architecture guarantees 100% material yield. Banish dust-generating regrind loops entirely from your sterile cleanroom environment.
✔ Independent Core Rod Temp Control
Precision thermal channels within each of the 30 core rods extract internal heat rapidly, providing master-level control over polymer distribution and locking in uniform wall thickness.
Working Principle: The Non-Stretch 3-Station Cycle
The ZQ135 achieves unparalleled structural container integrity by avoiding molecular shear. The cycle relies on thermal memory and precise radial expansion.
- Station 1: Preform Injection. The 70mm screw injects a massive 650g melt shot into the 4Cr13 steel cavities over the core rods. The expansive 6+N barrel zone system precisely dictates the hold pressure curve, forming a flawless neck and setting the exact container weight.
- Station 2: Blow Molding. The precision angle divider indexes the preforms 120°. Inside the chilled Mg-Al blow molds, the preform expands via pure pneumatic pressure. Internal cooling fluid within the core rods extracts heat rapidly, freezing the ≤±1% uniform wall.
- Station 3: Automated Stripping. The 280mm stripping stroke mechanically ejects all 30 containers simultaneously onto the conveyor. No human interaction, fully automated yield.
Applications & Material Suitability
The ZQ135 is explicitly mapped for non-PET polyolefins. The 22:1 screw perfectly homogenizes HDPE, LDPE, PP, PS, ABS, PCTG, EVA, and Eco-friendly Corn Material.
- Pharmaceutical Bottles: Mass production of sterile eye drop vials, solid-dose pill packers, and liquid medication containers demanding absolute GMP compliance.
- Cosmetics Packaging: Ultra-clear, thick-walled PS premium cream jars, mascara tubes, and roll-on applicator spheres.
- Precision Plastic Container Machinery: High-volume production of seamless LED lamp covers and specialized geometric housings.
Turnkey Custom Mold Solutions
Through our dedicated in-house CNC machining, we offer Replacement mold capabilities and brand-new custom cavities for the massive 1300x500mm tooling plates. We optimize 6+N hot runner systems to ensure rheological parity across all 30 cavities, providing Rapid Mold Changeover Support.
Full-Process Quality Control
Every ZQ135 undergoes a rigorous 4 S Dry Cycle Test and Clamping Force Verification (proving the 1350 KN lock) before shipping. Stringent Safety Interlock Validations and Air Leakage Tests ensure your machine arrives fully compliant with global CE directives and FDA contact material standards.
5-Step ZQ135 Selection Guide (IBM Specific)
Use this process engineering methodology to confirm the ZQ135 aligns perfectly with your production parameters.
① Confirm Bottle Volume & Neck Size (IBM Sweet Spot: <500ml)
While rated up to 2000ml, the colossal 1350KN clamp force provides maximum ROI when generating high-cavity layouts (up to 30 cavities) of 10ml to 500ml medical/cosmetic containers.
② Select Material Type (Non-PET Focus)
Validate your resin. The non-stretch IBM cycle is expressly designed for HDPE, LDPE, PP, PS, and ABS. (Projects requiring PET biaxial orientation must utilize ISBM technology).
③ Determine Daily Output Target
Forecast yield using the machine’s rapid 4 S dry cycle baseline, adding exact plasticizing thresholds dictated by your container’s wall thickness.
④ Match Tooling to the 1300x500mm Platen
Map your cavities. The 1350 KN clamping force securely houses a 30-cavity configuration for 10ml bottles or 18 cavities for 100ml bottles, optimizing cleanroom floor space.
⑤ Choose Cleanroom Auxiliary Equipment
To protect pharmaceutical integrity, utilize an oil-free compressor for pharmaceutical packaging to supply the 0.7 M³/min blow air, alongside a robust 4 M³/h industrial chiller.
Turnkey Installation, Debugging & Automation
Deploying a massive 18-Ton pharmaceutical asset requires precision. Our precision IBM molding solutions team conducts rigorous Pre-Installation Checklists, verifying heavy foundation leveling and 95 KW total power grid capacities.
During commissioning, we lock the Process Parameter Window, utilizing the high-precision angle divider to map the 3-station indexing precisely. We implement strict maintenance protocols for the 14 MPa dual-hydraulic system (37+37 KW), ensuring your pharmaceutical bottle making machine achieves decades of reliable OEE without pressure drops.
