广州What is the relationship between the wall thickness uniformity of blow molded products in Dalian and the production cost of the products?

As an important plastic product, Dalian blow molding products have a wide range of application prospects. With the advancement of technology and changes in market demand, blow molding processes and products will continue to be optimized and innovated, providing more efficient, environmentally friendly, and multifunctional solutions for various industries. Intelligent production is an important trend in the blow molding industry. By introducing automation equipment, robots, and IoT technology, production efficiency can be improved, labor costs can be reduced, and product quality can be enhanced.

Blow molding technology can produce high-precision and sterile medical containers, such as medication bottles, infusion bags, medical liquid storage tanks, etc. These products need to comply with strict hygiene standards. Blow molded products can be seen everywhere in daily life, such as plastic toys, storage boxes, trash cans, etc. These products usually have the characteristics of being lightweight, durable, and easy to clean.

What is the relationship between the wall thickness uniformity of blow molded products in Dalian and the production cost of the products?

1、 Raw material cost: uniformity affects material utilization rate

Uneven wall thickness leads to material waste

If the local wall thickness is too thick, additional raw material consumption may be required to meet the overall strength requirements (for example, if the average wall thickness of a container is designed to be 2mm, and the local wall thickness reaches 3mm, the overall material consumption may increase by 10% to 20%).

Uneven wall thickness may lead to excessive product weight, further pushing up the procurement cost of high-altitude materials.

Optimizing material distribution with uniform wall thickness

Uniform wall thickness can evenly distribute materials in the mold and reduce redundant materials. For example, by designing the mold head and adjusting the process, the circumferential wall thickness error of the container can be controlled within ± 5%, which can reduce material costs by 5% to 10%.

2、 Production efficiency cost: Uniformity affects production stability

Uneven wall thickness leads to an increase in scrap rate

Local thinness can easily cause product breakage (such as the thin shoulder area of the bottle being blown during blow molding), while excessive thickness can prolong cooling time and production cycle.

Data shows that when the wall thickness error exceeds ± 10%, the scrap rate may increase from 3% to over 8%, increasing the cost of downtime, mold replacement, and debugging.

Uniform wall thickness improves production efficiency

Uniform wall thickness ensures consistent cooling speed of the product, which can shorten the cycle time (such as reducing cooling time from 20 seconds to 15 seconds) and increase equipment capacity (increasing hourly output by 10% to 15%).

Stable process parameters reduce the frequency of manual debugging and lower labor costs.

3、 Mold and equipment cost: uniformity depends on high-precision mold

Uneven wall thickness requires higher mold accuracy

If the product wall thickness tolerance requirement is strict (such as ± 0.1mm), high-precision die heads (such as adjustable multi-layer die heads) need to be customized, which may increase the mold cost by 20% to 50%.

Uneven wall thickness may lead to uneven wear of the mold (such as excessive flushing of the mold mouth), shorten the mold life, and increase maintenance or replacement costs.

Uniform wall thickness reduces mold complexity

For products with low precision requirements (such as wall thickness tolerance ± 15%), standard molds can be used to reduce initial investment.

Uniform design reduces stress concentration in molds, extends service life (such as increasing from 500000 production cycles to 800000 cycles), and dilutes single production costs.

4、 Post processing and Quality Inspection Costs: Uniformity Affects Quality Control

Uneven wall thickness increases quality inspection and repair costs

It is necessary to increase the sampling frequency (such as increasing from once per hour to once every half hour), or introduce online detection equipment (such as laser thickness gauges) to increase quality inspection costs.

Unqualified products require manual selection or rework (such as cutting and remelting), which is time-consuming and labor-intensive.

Uniform wall thickness simplifies quality control process

Stable wall thickness can reduce quality inspection processes, and even use automated detection (such as visual inspection systems) to improve efficiency.

A high qualified product rate (such as ≥ 95%) can reduce rework and scrap costs.

5、 Long term cost: Uniformity affects product competitiveness

Uneven wall thickness may lead to hidden costs

If the product fails to meet performance standards due to wall thickness issues (such as insufficient load-bearing capacity), it may face customer complaints, returns, or brand reputation damage, indirectly increasing public relations and after-sales costs.

Uniform wall thickness enhances comprehensive benefits

High quality products can be sold at a premium (such as a 5% to 10% increase in unit price), while reducing the risk of long-term customer loss and diluting market expansion costs.

PE is a commonly used blow molding material with good toughness, chemical resistance, and processability. According to different densities, PE can be divided into high-density polyethylene (HDPE) and low-density polyethylene (LDPE). HDPE is commonly used in the production of hard containers such as oil drums, water buckets, etc; LDPE is used to produce soft containers such as plastic bags, films, etc.