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At drinktec in September in Munich, Netstal will show the newest model in its PET-LINE of presses for molding PET preforms: the PET-LINE 3000 with 306 metric tons (m.t.) of clamp force and side removal for molded preforms. The PET-LINE range launched in the fall of 2020 with a 408 m.t. model capable of running molds up to 128 cavities. The PET-LINE 3000 can run preform molds up to 96 cavities with a lock-to-lock time of 1.9 seconds. Going forward, Renzo Davatz, Netstal CEO said in a release that a 510 m.t. model is already under development. Netstal branched out from top-entry preform removal systems in 2020, when it began to also offer side-entry systems, noting that this additional option differentiates the company in the preform space.

PET-LINE 3000 machines can be ordered now with the first models already running at customer sites, according to Netstal. In its own testing against unspecified competitive machines, Netstal reported that the new PET-LINE, running existing 96-cavity molds and post-mold-cooling stations, achieved 20-25% energy use reductions and greater throughputs thanks to faster cycle times. These energy savings were achieved by applying the adaptive control and the latest generation of drives and inverters, in addition to an electric toggle, which doesn’t use a ball screw.

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The adaptive control that is part of the aXos machine controller allows the PET-LINE to learn the weight of the mounted take-out gripper and automatically optimize driving profiles for fast removal. The machine also estimates the mounted mold weight and optimizes closing and opening movement times. This reportedly means the drives are always equally loaded, boosting efficiency and power yield. Netstal says these optimizations occur automatically and do not require control expertise on the part of the process technician. The Smart Operation feature, which is standard, stores the entire sequence, which can be completed in four key strokes.

The optional Cycle Guard feature monitors power supply to the machine and can ensure sufficient energy is provided to the press to bridge power failures leading to short shots, even in the millisecond range. For a prolonged power outage, the feature allows the current cycle to be completed, with preforms finished and ejected, with production halted in a controlled fashion to avoid mold and/or machine damage.

Real-Time Inspection

The integrated Pecolux inspection system from IMD Vista monitors and documents preform quality in real time, as quality deviations are checked in continuous inline operation. In addition to key physical features of the preform, such as the gate and the thread, the system also checks the preforms for color differences, black specs, bubbles and crystallinity.

Sustainable Preforms With Tethered Caps Molded

At drinktec, Netstal is molding 10.5 g CSD preforms for 0.5-liter PET bottles. The 72-cavity mold is supplied by MHT Mold & Hotrunner Technology. Austria’s Eisbär Trocknungstechnik handles material preparation and the dehumidifier, with the chiller provided by Swiss company ef cooling. Equipped with a GME 30.40 thread, the preform already meets the new EU requirement for tethered caps. This standard dictates that starting in July 2024, caps must remain attached to the bottle after opening. PET granulate from the Neogroup company is processed, which consists of 25% chemically recycled PET.

The new PET-LINE comes with the latest generation aXos control system, equipped as standard with Smart Operation.
Photo Credit: Netstal