Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - in.blow (In.blow - new improved injection blow moulding system for production of thermoplastic bottles)

Teaser

• What is the problem/issue being addressed?Packaging is the largest user of plastics in Europe, representing 30% of the overall 46 million tonnes used in plastic conversion. Moreover, the plastic packaging industry in Europe was valued at €255 billion in 2014...

Summary

• What is the problem/issue being addressed?
Packaging is the largest user of plastics in Europe, representing 30% of the overall 46 million tonnes used in plastic conversion. Moreover, the plastic packaging industry in Europe was valued at €255 billion in 2014. Particularly, the blow-moulded bottles and packaging containers industry is highly competitive and fragmented. The most important strategy to success in this demanding marketplace is specialization. Currently, a blow moulder must differentiate himself from competitors through its expertise in producing containers that meet their customers’ unique packaging requirements. As a result, this is a very dynamic and evolving industry, where lack of innovation is mainstream problem in the sector.

The packaging manufacturer sector (our customers) is demanding for innovative solutions that will respond to the increasing trend of people looking for convenient and portable packages. Packaging manufacturers need to develop solutions that provide barrier properties, aroma retention, light weight, ease of use, and flexibility to their products. The importance of a convenient packaging is required by different kinds of industries such as: food, pharmaceutical, cosmetics, or personal care. Furthermore, rigid packaging such as cartons, boxes, and glass bottles cannot provide the shelf life, barrier properties, and ease of use required by most end products.

• Why is it important for society?
The in.blow system addresses the need to increase the competitiveness of European manufacturing industries through the use of advanced and cutting edge technology. Furthermore, developing in.blow we want to be a relevant participant in Industry 4.0 revolution in terms of reducing energy consumption. On the other hand, the European plastics converting (EU27) industry is composed of nearly 50,000 companies that directly employ more than 1.6 million people. The sector is mainly composed of SMEs employing on average only 24 people fulltime and creating a turnover in excess of € 280 billion per year. Furthermore, the European Plastic Converters Association (EuPC) claims that many European companies are under pressure from the up and coming Asian and Turkish markets, while fresh competition from North Africa and the Middle East is adding more players to the game. At this time, the European plastics converting industry is still benefiting from close networking with polymer manufacturers regarding innovative materials as well as from partnerships with suppliers of moulds, machinery and process technology. In this context, European plastics converters continue to be a key driver of innovation in customer industries. However, SMEs are missing the train of advanced manufacturing because existing proprietary technologies are too expensive and do not provide the flexibility required in highly dynamic industrial environments. The in.blow project will bring into the market a solution that is affordable for SMEs. It will also provide an economic option for large companies who want to optimise the costs of their plastic manufacturing processes. The project will reinforce European leadership in Injection Blow Moulding sector dominated by Asia and North America, leading for decades.

• What are the overall objectives?
Our main objective is to analyse the market opportunity of our project. In order to achieve our goal, we will do a Feasibility Study that:
• Analyse of our internal company resources to ensure our capacity to develop a commercial network according to the commercialization strategy at short and long term.
• Define a strategy for growth by defining strategic alliances for in.blow commercialization and implementation.
• Integrate the results of the feasibility study into a consolidated business plan.

Work performed

Phase 1 of the SME Instrument has led us to re-assess our business model. Therefore, the business plan developed as part of Phase 1 of the SME Instrument has focused on assessing the business opportunity of European and American markets opportunities.
The conclusions of the business plan have confirmed that the business idea is solid. It represents a real breakthrough for our company and for the sector of plastic packaging manufacturer.

We have assessed the technical and commercial feasibility of bringing into the market a new IBM mould. The key results are:
• Technological: Technical specification for the most used containers and asses the requirements for performance validation.
• IPR and knowledge protection: Analysis of data protection requirements and definition of the IPR strategy.
• Market and commercial: Development of a market study (including in-depth analysis of competitors and competitive solutions and market segmentation by industry and geography); undertook a benchmarking analysis of the competitive factors of the in.blow technology
• Business plan: Delivery of an initial business plan for the in.blow project, including investment plan and financial mode

Final results

The progress beyond of the state of the art is summarised below:
• Complex preform transfer mechanisms is eliminated by the use of a single combined blow moulding equipment.
• In.blow has a construction that it can be used in any typical injection moulding machine, thus giving additional production flexibility to its user.
• In.blow can be implemented using a fully electric injection moulding machine, if required by sanitation and cleaning criteria, for example for food and pharmaceutical applications.
• The single phase process has lower energy consumption than the two phase process because it eliminates the need to completely cool the preforms and reheat them for blowing.
• The compact mould eliminates the need for a rotating turret, the three stations and the alignment of these elements.
• The injection blocks and the blowing blocks are separated from each other and protrude from the base plate.
• The heat transfer can be performed concentrically to the cores to provide a uniform temperature to the preform and uniform cooling in the blown package. This provides a more uniform product while reducing the cycle time.
• In.blow project produces bottles without partition lines in the preform.

Website & more info

More info: http://www.molmasa.es/.