Plants for the production of pet bottles. Plastic bottles: PET production. The subtleties of manufacturing preforms for PET bottles

Due to its strength and low weight, PET is confidently replacing other types of products from the market. packaging materials. Glass bottle today it is practically not used for bottling beer, mineral water, milk, vegetable oil or juices, and PVC, cardboard or polystyrene are significantly inferior to polyethylene terephthalate in practicality and safety for the health of consumers.

The production of plastic bottles is a business that an aspiring entrepreneur can create with relatively little investment in any locality where there is a demand for such products. Large enterprises that produce drinks in large volumes, most often produce their own packaging, but there are also small oil mills, dairies, farms, sellers of draft beer and kvass who need PET containers and are ready to buy them regularly.

Business features

Entrepreneurs considering, among other advantages, can note the availability of production lines for the manufacture of PET containers: unlike machines for the production of glass products, such equipment is located on a free area of ​​​​20–30 m², and two or three people successfully manage its maintenance .

Of course, the requirements for the quality of products (especially those used in Food Industry) are invariably high: in order to avoid the appearance of defects, it is necessary to study the production technology of PET bottles, carefully adjust the processing modes of blanks, install special filters to prevent oil and polluted air from entering the containers, and also pay due attention to the choice of raw material suppliers.

Before purchasing a production line at the stage of developing a business plan for production plastic bottle it is recommended to find out the needs of future customers and determine the range of products of the enterprise: existing machines have limitations in terms of the capacity of manufactured products. For example, a universal semi-automatic machine can produce containers with a volume of 0.2 to 7 liters, while the production of 19-liter cylinders requires slightly different equipment.

The main method of processing plastic is heating followed by deformation, so the production of PET containers is accompanied by increased energy consumption: depending on the line performance, the total power of machines can reach 25–50 kW. Accordingly, the entrepreneur will have to at least make sure that the wiring of the workshop will withstand such loads, and in some cases, lay an additional power cable.

Business plan

Despite the noted difficulties, the production of plastic bottles is a promising type: processing technology polymer materials is constantly being improved, and the market for the consumption of PET containers is increasing by 7–8% annually.

Since the organization of such production is accompanied by quite impressive investments in the purchase of equipment and raw materials, a novice entrepreneur first of all needs to develop a business plan - a project that contains not only a description technological processes and distribution channels, but also the development strategy of the enterprise, the main goals and objectives. This document should also consider:

• Demand structure and market situation. It is possible that in this region there are already several enterprises producing similar products, and the main consumers have either installed their own lines for the production of PET bottles, or purchase containers from major suppliers at wholesale price. In any case, without analytical work it is impossible to determine the scale of production, the range of manufactured products and the required investment;
• Manufacturing issues. Based on information about the structure and nature of demand, one should find the most suitable premises for creating an enterprise, select the required configuration and capacity of equipment, develop a personnel plan, designate the main and secondary business processes;
• Profitability and payback period of investments. Currently, the competition in the production of plastic bottles is quite high, and therefore many manufacturers of PET containers operate with a minimum level of profitability.

To calculate the profitability and payback period of an enterprise, you need to take into account all the initial data - the cost of purchasing raw materials, the market price of products, the average salary in the region, the cost of renting a room, and even the acceptable percentage of defects.

Raw materials for the production of PET bottles

The main raw material for the production of PET bottles is polyethylene terephthalate (also known as PET or lavsan), which is a thermopolymer granulated under industrial conditions. The popularity of PET is due to its resistance to weak acids and alkalis, fats, gasoline and alcohols. As a packaging material, PET has other advantages:

• Light weight of a sufficiently large container;
• Possibility of wide application due to chemical neutrality;
• Wear resistance, durability and lack of fragility;
• High transparency, the ability to stain in any color.

The main disadvantage of the material is reduced barrier properties. Simply put, over time, carbon dioxide from the bottle can go out, and oxygen can penetrate inside.

However, unfinished products are produced from granules, and the so-called preforms are intermediate blanks that resemble threaded test tubes. Since the preform molding line is quite expensive, and raw materials for the production of plastic bottles in Russia have to be imported, many businessmen prefer to buy just such semi-finished products and use simple equipment to make containers as close to the consumer as possible.

Preforms are classified according to the main field of application - for filling:

• Mineral water or carbonated drinks;
• Juices and juice drinks;
• Milk, kefir;
• Beer and alcoholic beverages;
• cold tea;
• vegetable oil;
• Detergents, shampoos, household chemicals.

By weight

The mass of the workpiece determines the thickness of the walls of the bottle, as well as its final volume. For bottling beverages containing carbon dioxide, the strength of the container should be increased, so beer and soda producers use heavier preforms. On average, for the manufacture of a bottle with a capacity of 0.33 liters, a preform weighing 20–23 g is needed, for a liter - from 25 to 32 g, for a capacity of 1.5 liters - from 35 to 42 g, for a two-liter container - from 45 to 56 g.

Geometrically:

• Universal;
• shortened;
• Thick-walled.

In the production of bottles, a universal preform is most often used. With a weight of 42 g, such a blank has a length of 148 mm and a wall thickness of up to 3 mm.

By type of neck and thread:

• BPF or PCO (water, carbonated drinks, beer);
• Oil (olive and vegetable oil, vinegar)
• Bericap (paints, detergents, household chemicals).
• 38 (milk, kefir).

Production Methods

The classical technology for the manufacture of plastic bottles is based on the molding of the product by internal inflation. This two-step process includes:

• Injection molding preform. PET granules are heated to plasticization and the resulting viscous composition is filled under high pressure with stainless steel matrices. At this stage, a neck and a technological transport ring are formed, located slightly below the thread;
• Blowing bottles. The preform is heated in an oven until softened, and then air is fed into the preform - the bottle is inflated and takes on the final shape. The neck is intensively cooled to avoid deformation.

Due to the presence of two stages, suppliers of equipment for the production of PET bottles have the opportunity to combine configurations of production lines. Accordingly, the company can use:

• Single phase process. In this configuration, the injection molding machine and the blow molding machine are included in one production chain - it is enough to load PET granules into the machine to get finished products as a result;
• Two phase process. In this case, the finished preform after casting is sent to the warehouse or manually moved to the receiving hopper of the blow molding machine. This solution is more flexible, since it is much easier and cheaper to store a blank that takes up 12-20 times less space than the final product. In addition, several different products can be obtained from one preform, and in a single-phase process, such a change in assortment entails a complete reconfiguration of the entire line.

It should be noted that the raw materials used for the production of plastic bottles can also be secondary - defective or used bottles are crushed in crushers and sent to the injection molding machine hopper. Recycled preforms are much cheaper, but they cannot be used in the manufacture of food packaging and for blowing thin-walled products with complex patterns.

Production technology

Obviously, the stages of manufacturing PET containers are separate, unrelated processes. It is this circumstance that allows entrepreneurs choosing which production is profitable to open in 2020, at the initial stage, limit themselves to purchasing machines only for blowing, buying ready-made preforms different types as a raw material.

When buying equipment involved in the production of PET bottles, the price of the line and its components will depend on the country of origin, brand, capacity, availability additional options and service. However, the basic principles of machine operation will not change - the container manufacturing process will include:

• Loading preforms into the oven. At this stage, the quality of the blanks is controlled, checked for defects and placed on the receiver of the heating unit;
• Warm up. The preforms move through the oven, rotate around their axis and heat evenly, becoming soft enough to blow the bottle. In order for the temperature to even out along the thickness of the walls and reach a value of 110 ° C, after leaving the oven, the preforms are kept in air for some time;
• Blowing out The heated preform is fixed in an open mold. Then the second part of the matrix is ​​closed, and a special steel rod lowered into the preform preliminarily stretches it down to the height of the finished product. At the same time, air under pressure is supplied into the workpiece - the preform is inflated and occupies the entire available internal volume of the mold. From contact with metal, the plastic instantly cools and hardens. After that, you can raise the stem and open the die to remove the finished product.

Equipment

Technological lines for the production of PET bottles from preforms are offered in both semi-automatic and automatic configurations. In the first variant, the supply of blanks to working area and unloading of finished products is carried out manually, and in the second, these functions are performed by conveyors and manipulators. Automation of processes is advisable when integrating equipment for the production of plastic bottles in the bottling line finished products: so influence human factor is completely excluded. In combination with increased productivity (3,000–4,000 pieces per hour), blow molding machines are characterized by a high price (1.5–1.8 million rubles), so for start-up entrepreneurs, buying a semi-automatic machine is more preferable. The list of machines and devices necessary for the manufacture of plastic bottles in this case may look like this:

• Press forms. They are composite matrices made of stainless steel, the inner surface of which repeats the shape and dimensions of the finished product. For each type and volume of a bottle, a separate model is used - accordingly, an enterprise that produces a wide range of products uses several dozens of different molds in the technological process;
• Air compressor. It is used to supply pressurized air to the plastic bottle making machine. A typical model with a power of 12.5 kW creates a pressure of 16–25 atmospheres and is capable of delivering up to 500 liters of air per minute.

Semiautomatic blower. Produces finished products from preheated blanks by blowing in molds and subsequent cooling. Good equipment:

1. Prevents the ingress of oil from the air into the product;
2. When blowing, it cools the threaded neck, preventing deformation;
3. Equipped with water-cooled mold;
4. Allows you to remove finished bottles without touching their inner surfaces;
5. Cleans the air with filters, preventing the appearance of odor in finished products.

The productivity of equipment for the production of plastic bottles in a semi-automatic mode is from 1000 pieces per hour with a bottle capacity of 0.2 to 5 liters. Power consumption - 0.1 kW.

Preform heating oven. It is used to heat blanks to a temperature at which the plastic softens. The heating elements are nichrome coils placed in quartz tubes. The obligatory options for the furnace are the rotation of the preforms and the presence of zone heating, which makes it possible to obtain different temperatures along the length of the billet (the minimum temperature is in the region of the neck). With a capacity of 1000 items per hour, the energy consumption is 9.6 kW.

water cooler recirculating water supply. Structurally, it is a unit that cools water to 5–15°C, which is used to control the temperature of molds and finished products. Energy consumption - from 2.3 kW.

The composition of the technological line

Room requirement

Even with a small scale production of plastic bottles, the plant is recommended to be located in an industrial area away from residential buildings, since the work of the workshop is accompanied by the noise of mechanisms and the smell of hot plastic. Taking into account the small need for production space, it is more expedient not to buy, but to rent a room that meets the following requirements:

• Total area - at least 50 m²;
• Ceiling height to ceiling - not less than 4 m;
• The workshop must have engineering communications - water supply, sewerage, as well as a power line with a voltage of 220/380 V and a power of 25–30 kW (cable with a cross section of at least 10 mm² per phase).

The workshop space must be divided by stationary partitions into:

• production area;
• Warehouses for preforms;
• Warehouses for finished products;
• administrative premises;
• Bathroom.

Due to the fact that the production of plastic bottles involves the operation of high-temperature equipment, it is necessary to ensure compliance with fire safety rules in the production area - do not store combustible and flammable materials, line the floor and walls with heat-resistant materials or concrete.

Staff

Three people are needed to maintain a small semi-automatic plastic bottle production line: a foreman who sets up the equipment and controls production processes, directly the operator of the machine, as well as an auxiliary worker, who is in charge of the movement of raw materials and finished products, loading and unloading and auxiliary operations.

Enterprise staffing

Financial investments and profit

As a business, the production of plastic bottles requires investments not only in the preparation of the premises and the purchase of equipment: the entrepreneur will also have to purchase the first batch of raw materials (preforms) and invite specialists to set up the operating modes of the production line. In addition, in order to stimulate sales, taking into account the capabilities of modern marketing tools, it is advisable to order the development and promotion of the company's representative office on the Internet.

Initial investment

The amount of operating costs taken into account in the business plan for the production of PET bottles is determined not only fixed costs(wages, rent of premises), but also variables (payment for electricity, purchase of raw materials). To calculate the maximum values, it should be assumed that the shop works in one shift (8 hours) with a full load for a month (25 working days).

Current expenses

Name	Amount, rub.
IP insurance premiums	2300
Workshop rental	25000
payroll fund	90800
Payment for electricity 5000 kW per month	30000
Administrative expenses	5000
Fare	10000
Marketing	10000
Tax deductions	12000
Purchase of preforms	720000
Total:	905100

With a line capacity of 1,000 items per hour, the total volume of products produced per month will be 200,000 pieces (190,000 pieces, taking into account the allowable marriage of 5%). Calculate economic indicators you can use the example of PET bottles with a capacity of 1.5 liters:

• Standard preform weight - 35–38 g;
• The wholesale price of the preform is 3.55–3.70 rubles (3.60 rubles on average);
• The wholesale price of a colorless bottle is 4.95 rubles, a brown bottle is 5.10-5.30 rubles (an average of 5.15 rubles).

The monthly turnover of the enterprise when selling 190,000 products at a price of 5.15 rubles per piece will be 978,500 rubles, and net profit- 73400 rubles with a profitability of 8%. The payback period of investments is 22 months.

Obviously, in the manufacture of plastic bottles, the price of the preform and the cost of the finished product are decisive, so many enterprises are trying to get additional profit by increasing turnover. In this case, this problem is solved by purchasing a second semi-automatic blow molding machine (the design of the furnace allows simultaneous operation with two machines).

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Business Advantages and Disadvantages

Entrepreneurs choosing what kind of business to do in Russia in 2020 should be guided not only by the required value when analyzing their preferences start-up capital, potential market capacity and complexity of technological processes: any method of generating income is characterized by a set of certain advantages and disadvantages, which often determine the prospects of a particular area of ​​activity. To positive aspects business in the production of PET containers include the following:

• With no alternative for the foreseeable future, plastic bottles will continue to be the most popular packaging;
• PET is easily recycled, which makes it possible to open a plastic bottle recycling facility and obtain preforms from recycled materials;
• Exists a large number of preform manufacturers, so you can always find preforms good quality at the right price;
• Thanks to the huge number existing species packaging business can be expanded through the range, without increasing production space;
• For the organization of the enterprise does not need large premises;
• Due to the low weight of the container, transport costs will be minimal.

Of course, the production of PET bottles is a business that also has certain disadvantages:

• It is necessary to carefully monitor the quality of products, to control the absence of marriage, turbidity, foreign smell;
• If the city already has an enterprise selling PET bottles, you will have to look for a free niche or refuse to implement a business idea;
• A consequence of the previous drawback is the difficulty in finding an experienced specialist to set up the equipment or the need for his training.

conclusions

The method of manufacturing PET containers from preforms looks simple, understandable and worked out to the smallest detail: it is enough to heat the preform to a certain temperature and supply air under pressure inside. For entrepreneurs who are interested in the business of producing plastic bottles, the video material will help to get a better idea of ​​the main technological processes.

It should be noted that in reality the quality of the finished product is influenced by many factors - the correct choice of the heating mode, the initial and final blowing pressure, the speed of lowering the stretching rod: at a low level of profitability, an error or inaccuracy in setting up the equipment can increase the reject rate and turn the enterprise into a loss. Therefore, an entrepreneur needs to equally pay attention not only to minimizing related costs, but also to the technical component of production.

Colorless bottles are made by agreement and partial prepayment.

product, throat type	volume, L.	available colors	price from 10 000 pcs.	price up to 10000 pcs.	lid/handle	image
Bottle of BPF	0,25		negotiable	negotiable	50kop.
Bottle of BPF	0,4	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable
Bottle of BPF	0,5	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable
Bottle of BPF	0,5	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	negotiable
Bottle of BPF	0,5	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	50kop.
Bottle of BPF	0,6	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable
Bottle of BPF	0,6	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	50kop.
Bottle of B.R.C.	0.7 (1kg condensed milk)	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	70kop.
Bottle of BPF	1	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	50kop.
Bottle of BPF	1	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	50kop.
Bottle of BPF	1	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.		negotiable	50kop.
Bottle of BPF	1,5	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	50kop.
Bottle of BPF	2	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	5.5 rub.	negotiable	50kop.
Bottle of BPF	3	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable
Bottle, neck 48mm	3	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	negotiable
Bottle, neck 48mm	3	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	negotiable
Bottle, high neck	4	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	included
Bottle, high neck	4,2	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	included
Bottle with 38 mm neck	4,3	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	negotiable
Bottle, high neck	4,5	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	included
	4,8	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	included
Bottle, high/low neck	5	colorless, brown, blue, matt white, green, matt green, matt black, matt yellow, matt red, matt orange.	negotiable	negotiable	included

Main types and advantages of PET bottles

Product types

The classification of PET bottles is based on several parameters of the finished product. The main ones are the following:

• light transmittance. The container can be transparent, darkened, matte. In the first case, it is used for bottling lemonade, juices, and vegetable oils. In the second - for the sale of low-alcohol drinks, balms, tinctures of medicines. The purchase of opaque plastic bottles is most often relevant for manufacturers of household chemicals and car products.
• Wall thickness. It is selected depending on the purpose of the container. If bottles made from PET will be used to store non-aggressive substances, then standard products (0.1-0.5 mm) will do. Household chemicals must be poured into multilayer containers containing a polymer. For highly carbonated drinks, containers are produced, which include nylon (passive barrier). In the case when you have to work with reagents, you need PET products that are resistant to UV rays (active barrier).
• Volume. Plastic bottles vary in size. You can order capacious containers or buy small PET bottles.

Benefits of bottles made from PET

This container is very convenient for storing and transporting liquids of almost any kind. The basis for the manufacture is polyethylene terephthalate, a material that is now actively used for the manufacture of containers in which both drinks and food are stored.

Plastic containers for liquids are in high demand, which is explained by a number of its advantages:

• Ease of use. During transportation, the probability of damage to PET bottles is minimal.
• Variety of forms. Application in practice modern technologies allows you to get different capacities. Preforms are used (PET bottles are blown) or the extrusion method.
• Branding opportunity. Labels and other promotional products can be glued to the surface of plastic bottles.

We have been producing PET bottles for many years, we can fulfill orders of any complexity.

What determines the price of PET bottles?

The pricing factors in the sale of PET bottles are:

• volume;
• features of the used PET (regular, multilayer, etc.);
• complete set (presence/absence of cover and handle);
• order specifics (small, medium, large wholesale).

Need to buy PET bottles in Moscow? Contact Ultraplast

Our company is a reliable supplier of containers made using PET. In Ultraplast you can buy plastic bottles for water and other liquids. The range of products is periodically increased.

Clients are provided with a number of important guarantees, including:

• high quality products, confirmed by certificates of conformity;
• a large selection of plastic bottles, containers of different volumes are produced - from 0.25 l to 5 l;
• optimal prices, there are no intermediary margins in the cost of products, we are a direct manufacturer, the sale of plastic containers for liquids is carried out on favorable terms;
• flexible system of discounts, we are focused on long-term cooperation, therefore we create the most favorable conditions for customers;
• services are inexpensive and fast delivery plastic bottles to your facility.

Do not miss the opportunity to buy PET containers in Moscow at a competitive price. To clarify the terms of cooperation, please contact our managers.

PET bottles come in a variety of sizes and shapes. In shop windows, you can often find standard bottles with an elongated neck or a domed top, or containers of bizarre shapes in the form of a barrel and an hourglass. Have you ever wondered how plastic bottles for various liquids are produced?

Stage one. blank.

For the production of PET bottles, a PET preform must first be made.

PET preform is a special blank, which is made of polyethylene terephthalate by injection molding using specialized high-performance injection molding machines. Such blanks must have a high level of quality for blowing bottles, cans and vials, therefore, for their production, as a rule, high-quality virgin PET granules are used. It is also possible to use recycled PET granulate.

Workpieces may have different sizes, diameter, weight and color, depending on the parameters of the container for which they are intended. The PET preform manufacturing process includes three stages:

• plasticization of the granulate,
• granulate injection,
• cooling.

Factors such as the minimum moisture content of the granulate and the workmanship of the hot runner mold can affect preform quality. The mold is a device in which the shaping of the workpiece is carried out.

Stage two. The choice of bottle production technology.

There are two main types of PET bottle production: two-stage production and one-stage production. Consider the main differences between these technologies.

Two-stage production PET bottles is the traditional and most common method of making PET containers. It consists in the fact that the preforms are placed in a special oven, where they are heated and then fed through a conveyor for blowing. Depending on the equipment, blowing can be done automatically or manually.

Bottle blowing is often carried out at the final point of use of the container. This is due to the relative cheapness of semi-automatic blow molding equipment and the ability to minimize transportation costs.

It should be noted that blowing bottles of complex shapes will require more advanced equipment, greater blowing pressure, as well as qualified employees. Fully automatic blow molding ensures high productivity and stable quality of PET bottles.

Mono-stage production- this is modern way production of PET bottles on special single-stage injection-blowing devices. They allow to produce a full cycle of container manufacturing - from PET granulate to the finished product. At the same time, the manufactured preform is not discarded, but immediately goes to blowing the bottle.

The advantages of this technology include the high quality of the products obtained (no scratches, a more accurate neck), the possibility of producing bottles with any type of neck, a more uniform distribution of plastic, which allows saving material and improving appearance containers.

Stage three. Ready PET bottles.

Whatever the technology used to make PET bottles, in any case, they have undeniable advantages over most other types of containers.

Ready-made bottles made of polyethylene terephthalate are highly resistant to water, fat, acids, alkalis, temperature changes and mechanical damage. Plastic bottles are equipped with screw caps, which guarantee the tightness of the packaging and the complete preservation of product quality for a long time.

PET bottles are used for packing mineral water, soda, kvass, beer, milk, kefir, fruit drink, butter and much more.