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Visual and thermal defect inspection systems
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Get them answered by the team at Amcor.
Background

Thick-walled preforms are used to create containers that need to be strong, durable, and reusable. These containers are made through a 2-step stretch blow molding process. In the first step (injection process), plastic is injection molded into a preform - a compact, often cylindrical form with a threaded neck, designed for the specific container shape. In the second step (blowing process), the preform is reheated, placed in a blow mold, and expanded with high-pressure air to form the final container. 

 

Processing heavy, thick-walled preforms into refillable containers poses challenges during both the injection and blowing processes. Thick-walled preforms are difficult to cool during the injection process and challenging to reheat during blowing. 

 

One of the main challenges of the re-heating process of thick wall preforms is obtaining balanced temperatures across the wall thickness of the preform. If the temperature difference (delta T) between the internal and external wall is too large, it can lead to defects such as cold stretching pearlescence and heat haze. 

 

Cold stretching pearlescence occurs when the preform is stretched at a low temperature, causing a whitish, streaky appearance due to uneven stretching of the polymer. On the other hand, heat haze results from overheating, where excessive crystallinity develops in the material, leading to a cloudy or opaque appearance in the final container. Both defects negatively impact the quality of the final product.

What we're looking for

We are seeking technologies, such as thermal profiling, vision systems, sensors, and image recognition, to identify and measure defects in plastic containers after the blow molding process. Specifically, we are looking for a method to easily identify and measure cold stretching pearlescence vs. haze from over-heating crystallization during the blow molding process or immediately thereafter. The intention is to use this information to make real-time adjustments and corrections to the blowing process.

Solutions of interest include:
  • An apparatus and method for the measurements.
  • Imaging (e.g. infrared and polarized light cameras) or in-line optical sensors coupled with automated defect detection.
  • Vision inspection systems.
  • Specialized instrument providing a full thermal profile of the preform, integrated with machine learning for real-time defect prediction and process optimization.
Our must-have requirements are:
  • Identify and measure areas that have either heat haze or over-stretch pearlescence (cold stretch) around the complete perimeter of the container.
  • Provide a graphic/visual feedback indicating the location of the crystallinity/pearlescence in the container.
  • Deliver fast, verifiable, and repeatable results that can be used to adjust the blow molding process as it happens.
Our nice-to-have's are:
  • Graphic/visual interface.
  • Portability for use across different production lines.
  • Ease of use, geared toward a production line environment.
  • Live monitoring system capable of in-line operation at blow molding speeds (~6000 bottles per hour).
Acceptable technology readiness levels (TRL):
Levels 3-9
What we can offer you
Eligible partnership models:
Co-development
Equity investment
Supply/purchase
Sponsored research
Benefits:
Sponsored Research
$50,000, more can be considered depending on the proposal.
Data
Colorimeter and crystallinity measurements can be provided.
Facilities and Services
Amcor Rigid Packaging R&D Center, Manchester, MI. Injection, Blow Molding, Prototyping Lab, Quality Control Lab, 3D printing, CAD and FEA (in house simulation available).
Expertise
Packaging expertise: Packaging design, Simulation (FEA), Injection and Blow Molding Processing, Quality Control and Testing.
Tools and Technologies
Injection and blowing machines available, and off-line existing lab equipment (color spectrum analyzer and light scatter crystallinity measurement).
Who we are

We solve packaging challenges, around the world every day. We develop differentiated products, services and processes to protect your products and the people who rely on them, all around the globe. Drawing on unrivaled heritage in design, science and manufacturing, more than 1000 R&D experts are innovating new materials, formats and technologies to better protect your products.

In 2018 we pledged to develop all our packaging to be recyclable or reusable by 2025. On our journey to our 2025 pledge we are innovating across various sustainability options, delivering you more sustainable packaging solutions under the new EcoGuard™ brand.

 Learn more
Reviewers
GC
Gregory Carpenter
Senior Scientist
FB
Frederick Beuerle
Sr. Director, Innovation & IP
LL
Lissette Lozano
Advanced Product Development Manager
FA
Farhan Ahmad
Sr. Scientist
LC
Luis Carvallo
Principal Engineer
Q&A with Amcor

The Q&A is now closed.

Sort by:
Most upvoted
Q.
What are the expectations with IP?
1
A.
There are several options for managing IP. We can discuss your expectations once we've met to discuss your proposal.
GC
Gregory Carpenter, Senior Scientist, Amcor
October 24, 2024
Is this response helpful?
0
0
Q.
I was wondering why the standard inspection of empty containers (for recycling) would not be applicable in your case? It could happen immediately after the blow molding process.
1
A.
Differing from the inspection of empty containers for recycling, we are looking for more than 'color' and whether or not the container has pearl or heat haze. Ideally, the inspection equipment will be able to classify the type of defect between these two visually similar defects. The equipment should then be able to alert the operator to make the appropriate adjustment. Does that make sense?
GC
Gregory Carpenter, Senior Scientist, Amcor
October 24, 2024
Is this response helpful?
2
0
Q.
We have Thermal IR camera with thermography optn (to capture temp. variation up to fraction of deg C). If there is option to mount camera to view full surface while blow moulding, then we can build solution. pls cnfrm
1
A.
While blow molding, the container will be within the mold. During conveying, there will be several potential locations to mount a camera or inspection system.
GC
Gregory Carpenter, Senior Scientist, Amcor
October 29, 2024
Is this response helpful?
0
0
A.
Is the mold material thermal conductor ? so that we can get thermal profile of outer surface of container while blow molding in progress. also can you pls describe heating system being used while blow molding (to know how it could be controlled for uniformity of temp profile) - mainly to check how to detect temp. non-uniformity during molding and possible ways to control in real-time to eliminate fault (than to detect after molding). Post inspection could be done with day light camera and image processing.
1
A.
The mold is made of steel and held within a mold shell within a mold clamp. Glycol is flowing through the mold to maintain a constant mold temperature. Air used for blow molding is 'cool.' The PET preform is heated prior to the mold, through a series of oven banks, to create a 'temperature profile' through the preform. If this isn't clear, I may be able to send you a representative video of 2-step PET blow molding. Thanks for the questions!
GC
Gregory Carpenter, Senior Scientist, Amcor
October 29, 2024
Is this response helpful?
0
0
A.
Thanks Gregory, A sample video will definitely be helpful to understand better. Then we will get a better idea of when, where, and how to sense temperature anamoly (as I am more curious to see how can we eliminate "root Cause" by early detection
1
Q.
For the moment, is the measurement to happen while the parts are moving fast? Are they turning? Also is there any threshold on the size of defects to pass or fail? For example a haze of 1mmx1mm is a fail?
1
A.
Parts are produced between 1500 and 3000 bottles per hour. They are not rotating. The size for a 'failure' is fairly large. These are all great points that we can discuss.
GC
Gregory Carpenter, Senior Scientist, Amcor
October 29, 2024
Is this response helpful?
0
0
Q.
How is it possible to access/collect the data? Are you going to provide a set of samples to be used for testing and validation or do we need to move to the facility to conduct research? Thanks in advance
1
A.
We can provide samples of containers with the various defects to use for sensor evaluation.
GC
Gregory Carpenter, Senior Scientist, Amcor
October 29, 2024
Is this response helpful?
0
0
Q.
I was wondering if you could provide the absorption or transmission spectra of the preform, along with its wall thickness and final size.
1
A.
The preform wall thickness is around 7.2 mm and the final container wall thickness is close to 0.75 mm. We can get absorption and transmission spectra to you as part of the project. For the moment, I would assume literature values for amorphous polyethylene terephthalate.
GC
Gregory Carpenter, Senior Scientist, Amcor
October 30, 2024
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