XFORM GEN4 XP

Setting a new standard in PET preform manufacturing

The new XFORM GEN4 XP technology complements the GEN3 in the product portoflio and aims to target the most demanding applications, guaranteeing the highest preform quality and process consistency at the lowest manufacturing cost.

While CEOs will benefits from possibly the lowest conversion cost in the industry coming from extremely fast cycle time, record-high energy efficiency, lower-in-the-industry maintenance costs and full flexibility in using legacy tooling, operators will enjoy a brand new experience, thanks to the totally redesigned 21.5" HMI, self-setting process set-up, preform troubleshooting tutorial which ultimately deliver a top-level user friendliness.
 
 
 

Highlights:

  • Capability to install any generation of legacy tooling with no mold modification (including EOAT for the latest tooling generation)
  • High injection speed
  • Lock-to-lock below 2.5s
  • New increased-throughput XFlow™ screw design
  • More efficient post-mold cooling technology for record-low cycle times
  • Reduced energy consumption
  • GEN4 hot runner design for superior flow balance and low pressure drop
  • XMold™ technology for reduced melt friction and higher L/T capability
  • SmartLock™ stack design for unprecedented cooling for short-neck preforms
  • LongLife™ stack coating technology for superior mold life
  • Extremely low maintenance costs 
  • Record-long mold life
XFORM 500 GEN3

XFORM 500 GEN3

PET preforms production systems

XFORM 500 GEN3 144 CAVITIES

XFORM 500 GEN3 144 CAVITIES

High speed PET preforms production system

XFORM 500 GEN3 large size preforms

XFORM 500 GEN3 LARGE SIZE PREFORMS

Long preforms in PET production system

XFORM 350 GEN3

XFORM 350 GEN3

PET preforms production systems

XFORM 500 GEN4-NO VIBRATIONS

XFORM 500 GEN4-NO VIBRATIONS

XFORM 500 GEN4 system equipped with a 180Cav tooling running at a cycle time of 5.4 seconds. NO VIBRATIONS AT ALL!

Process steps: main features & benefits

Injection system
  • Servo-driven
  • Continuous low-speed screw rotation:
    • No power peaks for screw restart, lower energy consumption
    • @ 700 kg/h (0.80 IV): 34 RPM
    • Lower stress on the material
    • Lower IV drop (< 0.015 dl/g)
    • Lower AA generated by the extruder
  • Possibility to use color up to 4% with NO throughput drop
  • 4 shooting pot designs:
    • P105: 4.200 g
    • P125: 6.000 g
    • P140: 7.500 g
    • P145: 8.200 g
  • 2 screw designs:
    •  120mm: up to 1.000 kg/h (low IV)
    •  140mm: up to 1.480 kg/h (low IV)
  • Best-in-class injection system for PCR (flakes) applications: the lowest throughput drop @ 50% PCR
Durable clamp design
  • Very smooth closing profile
    • less stress to the tooling components in the clamp closing phase
    • less vibrations, affecting overall system reliability in the long term
  • Perfect cleanliness
    • durable clamp concept with encapsulated toggle levers & linear guidance of the moving platen
  • Low machine and mold service costs
    • no high-pressure hydraulic cylinder to rebuild periodically
    • durable clamp design allows for very low maintenance costs
    • best-in-class platen parallelism for long mold life
  • High platen thickness for virtually no deflection & extended mold life
  • Even tonnage distribution in all toggle links
  • Active mold protection system, monitoring clamp closing profile at every cycle
Injection Mold
  • We design preform molds featuring:
    • Largest operating window
    • Maximized part quality
    • Reduced maintenance cost
    • Wear-resistant coating to grant a longer mold live
    • Optimized cooling layout to support fast cycle times and save energy costs
    • Lowest mold platen deformation, precision and reliability
  • Our hot runner systems deliver:
    • Xflow™ technology with low pressure drop: best in class balancing
    • Increased injection speed, shorter cycle time
    • Optimal preform weight distribution 
    • Thanks to the smoothed channels extremely low PET degradation and avoided dead spots (low AA)
    • Easy maintenance
  • Our cold half delivers:
    • Proprietary LongLife™ technology: range of solutions capable to extend component life for preform mold cold halves.  8 million life cycles guaranteed (flash < 0.2mm) without need of components refurbishing
    • Significant reduction of refurbishment costs
    • Proprietary XMould™ technology: Sipa innovation which allows reducing the friction between the molten PET and the molding surface of the injection stacks during the injection phase. Two major advantages: shorter cycle times and ultra thin preform molding capability
    • SmartLock™ stack design for unprecedented cooling for short-neck preforms

Post-mold cooling
  • Cooling air flows from the neck to the gate:
    • cooler air inside the preform = better body and neck cooling
    • pin follows the preform geometry = higher air speed, better cooling effect
    • pin very close to the dome = better base cooling
    • no need to cool air with separate dehumidifier = less energy
  • Air cooler at the outlet of the transfer box to decrease air temperature for better preform internal cooling
  • Air intake: 20°C 
  • Preform transfer system is independent from the clamp movement:
    • better accessibility during mold changeover 
    • higher flexibility in adjusting the transfer box speed for guaranteed part removal
  • Preform transfer system supported by 2 points:
    • less stress on the whole structure
    • no risk of misalignment with EOAT
  • Excellent accessibility to non-operator side for mold changeover: up to 1m access

Materials


  • PET
  • OPP
  • PLA
  • Recycled PET
  • R-PET flakes

Type


  • Thin-wall preforms (for lightweight bottles for mineral water, edible oil)
  • Thick-wall preforms (for carbonated beverages)
  • Preforms for heat set bottles
  • Wide mouth preforms for jars
  • Long preforms for large size containers

Applications

Preform production systems series XFORM 250, 350 and 500 GEN4 can produce a wide range of preforms with excellent performance. 

Production range

XFORM 350 : CAVITATIONMAX PREFORM THREADZ DIAMETERROWS X COLUMNSPITCH
12830 mm34 mm16 x 850V 120H
9630 mm34 mm16 x 650V 155H
9630 mm34 mm16 x 650V 140H
9638 mm43 mm12 x 860V 140H
7243 mm48 mm12 x 663,5V 160H
4848 mm53 mm12 x 475V 170H
3263 mm65 mm8 x 485V 180H
2470 mm72 mm6 x 495V 190H
1675 mm80 mm8 x 2110V 360H
12110 mm110 mm4 x 3140V 240H
875 mm80 mm4 x 2110V 360H
XFORM 500 : CAVITATIONMAX PREFORM THREADZ DIAMETERROWS X COLUMNSPITCH
18030 mm34 mm18 x 1050V 110H
14430 mm34 mm18 x 850V 140H
12830 mm34 mm16 x 850V 140H
9638 mm43 mm12 x 860V 140H
9630 mm34 mm16 x 650V 140H
7230 mm34 mm12 x 650V 140H
7238 mm43 mm12 x 660V 140H
7248 mm53 mm12 x 675V 170H
4848 mm53 mm12 x 475V 170H
1675 mm80 mm8 x 2110V 360H

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