hypet preform systems (1)

Husky has been the leader in the preform

equipment industry for over 35 years with

more than 3 500 systems installed around

the world. HyPET® is our flexible preform

injection molding system capable of pro-

ducing over 110 000 preforms per hour. It

is available in seven sizes, ranging from 90

to 650 tonnes (100 to 715 tons) for molds

between two and 192 cavities.

All components of the HyPET system,

including the hot runner, mold, machine,

robot and post-mold cooling, are spe-

cifically designed to work together as a

fully integrated workcell to achieve the

Turnkey solutions for every application and volume

HyPET systems• Industry-leading productivity

• Highly repeatable and reliable

performance

• Easy-to-use operator

interface

• Energy efficient

• Optional High Performance

Package (HPP)

• Optional Recycled Flake (RF)

capability

• Optional Flex Mold for fast,

easy product and mold

change

• Combining HyPET with Husky

Services ensures customers

achieve the lowest total cost

of ownership over the

product life cycle

• Leading-edge auxiliary

equipment optimized for

Husky systems

HyPET Preform Systems

industry’s highest levels of productivity

and quality. In addition, we offer a diverse

range of services, including preform devel-

opment, preform prototyping, preform

lightweighting, mold conversions and mold

refurbishing.

For customers looking for a turnkey solu-

tion for preform production, Husky is the

single point of contact for plant design,

the complete injection molding system,

the auxiliaries and downstream product

handling equipment from our industry

partners.

HyPET systems located at a customer plant in Moscow.

HyPET features/overview

Better cooling for faster cycles

HyPET uses an integrated part cooling and

handling system called CoolPik®, which

features up to four cycles of balanced

cooling on the preform’s inner and outer

surface. This results in faster cycles and

better part quality in comparison to other

post-mold cooling systems that only cool

the outer surface.

Optimized technology

A wide range of extruders are available to

best match the equipment with the specific

needs of the application. Newly developed

HyFLO plasticizing screws minimize acet-

aldehyde (AA) generation and increase

mixing and plasticizing performance.

HyPET Preform Systems2

Collaborating with industry leaders to

bring the best technology

In addition to our own complete systems,

we work closely with other technology

partners to create innovative solutions.

From barrier systems to recycling technolo-

gies to new materials, we are continually

collaborating with industry leaders to bring

new technologies and products to market.

HyPET features/overview

“In June 2008, Western Container Corporation took on-time delivery of our latest preform

molding system. The 192-cavity Husky Injection Molding System was in production on

schedule. This installation and start-up was one of our best experiences with a preform

system integration in our history. It has cost-effectively expanded our production of a

broad portfolio of preform designs and colors for the Coca-Cola Company.

We now have the world’s highest output preform system resulting from a Western

Container Corporation—Husky collaborative relationship.”

Mike Andrysiak—President and CEO

Western Container Corporation

HyPET Preform Systems 3

PET Auxiliary Equipment

When purchasing a new Husky HyPET

system customers can choose Husky PET

auxiliaries that offer leading-edge designs

specifically optimized for Husky systems.

Husky assists customers by coordinating

the integration, testing and delivery of

complete turnkey systems that are opti-

mized for maximum productivity. Husky

is responsible for the complete workcell,

overseeing configuration, supply and

installation, as well as providing complete

support, service and parts complemented

by a comprehensive warranty. Most impor-

tant of all, customers get a single point of

contact to support them in the success of

their products.

By choosing Husky PET auxiliaries, cus-

tomers get a complete, integrated PET

system. This complete solution has mul-

tiple benefits, including improved energy

consumption, enhanced controls interface

and advanced feature capability. Auxiliaries,

including resin dryers, dehumidifiers, chill-

ers and soft-drop part handling, are all

centrally controlled through Husky’s Polaris

Control operator interface. Advantages of

this integration include:

• Control of entire molding system from a

single interface

• Remote connectivity through ServiceLink™

• Integrated alarm handling and notifi cation

for easy troubleshooting

• Assured total process control through SPC

HyPET with High Performance Package

The Husky High Performance Package

(HPP) is the result of refinements to the

entire HyPET preform system, including

mold, robot, injection unit, clamp and

auxiliary equipment. Only through this

coordinated effort has it been possible

to significantly improve molding cycle

times, while still producing preforms with

superior levels of quality. This new tech-

nology typically reduces cycle times by

approximately 15% compared to previous

industry-best cycle times.

The productivity improvements offered

by HyPET with HPP further reduce the cost

of PET packaging, making it even more

competitive with glass, metal and carton

alternatives.

HyPET Recycled Flake system

The HyPET Recycled Flake (RF) system is

specifically designed for manufacturing

preforms with high percentages of food-

grade recycled PET flake. An integrated

melt filtration system minimizes black

specks and other contaminants that can

negatively influence bottle quality. A new

extruder design enables improved process-

ing of pellet and flake blends.

The HyPET RF option enables molders to

begin using recycled PET or increase the

percentage used. Preform quality is

maintained or even improved, even with

increased recycled PET content. The end

result is a molding platform that can lower

the environmental impact of PET as a pack-

aging material without compromising part

quality.

Significant lightweighting benefits

EcoBase™ is a uniquely shaped preform

base that differs from the traditional

hemispherical design commonly seen

throughout the industry. By reducing the

wall thickness of the preform base to be

more consistent with the body, the new

shape allows for a weight reduction of the

overall preform by up to 2.5%. This results

in lower costs and a reduced carbon foot-

print.

Preform design optimized for specific

needs

Upon review of the intended produc-

tion equipment, Husky will optimize the

EcoBase preform’s dimensions to meet an

application’s specific blowing and perfor-

mance requirements. Easy to integrate into

existing molds, EcoBase requires minimal

changes to the preform system. In most

cases, no hardware changes to the blowing

machine are required.

Improved energy utilization during

reheat

The EcoBase preform design improves heat

absorption of the preform base during

blow molding. A traditional hemispherical

preform base is difficult to reheat because

most of the infrared energy is reflected off

the surface of the preform instead of being

absorbed. EcoBase provides greater control

of the reheat profile in the preform base

resulting in an improvement of up to 3% in

energy absorption during reheat.

Mechanical performance

During the blow molding process, bottles

with the EcoBase preform design demon-

strate better material distribution in the

base of the bottle. This is possible because

EcoBase eliminates the wasted material

typically observed around the injection

point, allowing for an optimized preform

base. Testing has shown mechanical per-

formance, including stress cracking, burst

strength and top load, is consistently equal

to or better than bottles blown from pre-

forms with the standard hemispherical

base shape.

EcoBase preform lightweighting

Potential weight savings

Mineral water Carbonated soft drink

500 ml—up to 0.3 grams 600 ml—up to 0.5 grams

1.0 liter—up to 0.6 grams 1.5 liter—up to 1.1 grams

1.5 liter—up to 0.8 grams 2.0 liter—up to 1.2 grams

Actual savings depend on original preform weight and dimensions

EcoBase offers up to 2.5% resin savings.

Case study

Application: 1.5 liter, (sparkling water)

Weight savings: 0.6 grams after base light-

weighting

Cavitation 96-cavity

Weight savings 0.6 grams

Cycle time 9.0 seconds

Annual resin savings190 tonnes

(209 tons)


Preform molds

As the world’s largest moldmaker, Husky

is able to deliver global tooling programs

for new molds or conversions of any size.

Preform molds are produced at dedicated

facilities in Canada, the United States and

Luxembourg. Husky continues to invest in

these state-of-the-art facilities to increase

capacity, reduce lead times and maximize

part quality. In-house test rooms are capa-

ble of testing all molds manufactured.

Husky preform molds are designed and

built to produce the highest quality pre-

forms at the best cycle times in the industry.

Preform molds are available from two up to

192 cavities.

Productivity

• Fast cycling due to specially designed

cooling circuits

• Part ejection sensors that monitor preform

transfer to the take-off plate, improving

cycle time

• Standard interchangeable mold compo-

nents; replacement parts available within

24 hours

• Two-piece cavity option allows the re-

placement of wear parts without changing

the entire cavity

Reliability

• Rugged design for long life

• Roller cams that actuate both the opening

and closing actions on the thread splits

• Ultra hot runners feature a spring pack

that eliminates resin leakage between the

manifold and the nozzle and longer valve

gate seal life

Part quality

• Lowest cavity-to-cavity weight and dimen-

sional variation as a result of best-in-class

manufacturing machines and processes

• Water hoses that are consolidated at

the bottom of the mold, eliminating the

potential for water marks on preforms

Ease of maintenance

• Connecting bars are driven by a mainte-

nance free cam assembly

• Stainless steel stacks eliminate molding

surface corrosion

Mold refurbishment

Maintaining best-in-class quality pre-

forms requires regular mold maintenance

and scheduled refurbishing programs.

Customers can quickly and easily convert

or refurbish their molds at any location

throughout Husky’s industry-leading net-

work of refurbishing centers.

Preform prototyping

As part of a conversion or new product

launch, Husky helps customers get new

bottles to market quickly by offering

preform development and prototyping

services. We are uniquely positioned to

develop preform designs that are opti-

mized for production scale molding. When

the preform design is final, we can imme-

diately scale up to a production mold by

transferring the project to our production

team.

Flex Mold

Flex Mold™ is a flexible, low cavitation PET

preform mold. Available in eight, 16 or 24

cavities, Flex Mold is ideal for lower volume

preform producers (producing between

five and 30 million units each year) or those

manufacturers who produce a range of

preform families.

Flex Mold:

• Reduces mold change times by one third

compared to conventional designs

• Eliminates the need to cool down and

reheat the hot runner during a preform

change

• Minimizes the number of components

that need to be replaced for a new pre-

form design

• Includes adjustable cams that can be used

for a variety of preform designs, thereby

reducing conversion cost

• Uses post-mold cooling tubes mounted

on lightweight “take-off bars” to eliminate

the need for a crane during take-out plate

changes

• Includes a mold water purge system to

improve mold change time and reduce

water spillage

Flex Mold is ideal for producing families of

bottles with common threads.


Applications

HyPET 90 HyPET 120 HyPET 225 HyPET 300 HyPET 400

Cavitation

output (mm/yr)

Cavitation

output (mm/yr)

Cavitation

output (mm/yr)

Cavitation

output (mm/yr)

Cavitation

output (mm/yr)

500 ml (17 oz.)

Carbonated soft drink

Neck Finish: 28 mm PCO

Weight: 21–25 grams

24

86.4

32

112.5

48

163.0

72

236.6

96

312.1

500 ml (17 oz.)

Bottled water

Neck fi nish: 26 mm PCF


24

148.1

32

197.4

48

296.2

72

418.7

96

547.7

500 ml (17 oz.)

RTD tea / Hotfi ll

Neck fi nish: 28 mm


24

63.6

32

84.8

48

127.3

72

186.0

96

246.0

473 ml (16 oz.)

Dairy

Neck fi nish: 30–38 mm


24

63.6

32

84.8

48

127.3

72

186.0

96

246.0

500 ml (17 oz.)

Aseptic juice

Neck fi nish: 38 mm Bericap


24

81.5

24

81.5

32

108.7

72

236.6

96

312.1

591 ml (20 oz.)

Hotfi ll juice

Neck fi nish: 38 mm VHS


24

41.7

24

41.7

32

55.6

72

123.0

96

163.0

3–5 gal (384–640 oz.)

Water

Neck fi nish: HOD Standard


—

—

—

—

8

4.8

16

9.6

16

9.6

1.5 l (51 oz.)

Sparkling water

Neck fi nish: 25–30 mm


24

77.2

32

102.9

48

154.4

72

224.4

96

296.2

330 ml (11 oz.)

Beer

Neck fi nish: 28 mm PCO


24

69.7

32

93.0

48

139.5

72

203.4

96

268.8

946 ml (32 oz.)

Food jar

Neck fi nish: 63 mm SP400


8

16.8

8

16.8

16

33.6

24

49.3

32

65.3

Broadest product range in the industry


HyPET 500 HyPET 650

Cavitation

output (mm/yr)

Cavitation

output (mm/yr)

144

458.3

192

552.9

144

791.7

192

893.2

144

362.8

192

446.6

144

362.8

192

446.6

128

407.4

144

414.7

128

215.0

144

229.1

24

14.5

—

—

144

435.4

192

527.8

144

395.8

192

483.8

48

96.7

—

—

Maximum preform mold cavitations

Maximum thread

diameter

HyPET

90

HyPET

120

HyPET

225

HyPET

300

HyPET

400

HyPET

500

HyPET

650

up to 30 mm 24 32 48 72* 96* 144* 192**

up to 38 mm 24 24 32 72* 96* 128* 144**

up to 43 mm 16 16 32 48 72 96 144**

up to 48 mm 12 12 24 32 48 72 —

up to 63 mm 8 8 16 24 32 48 —

up to 70 mm 6 6 12 16 24 32 —

up to 90 mm 4 4 8 12 16 24 —

up to 110 mm 2 2 6 8 12 16 —

* Available in both HyPET and HyPET with High Performance Package (HyPET HPP)

** Only available as HyPET HPP


For more than 50 years, Husky has been

building expertise through a knowledge

base that is unmatched in the injection

molding industry. That knowledge can be

accessed through Husky Services.

With Husky Services products and pro-

grams, a customer can develop and

implement a proactive strategy that bal-

ances preventative and predictive elements

—all geared toward achieving industry-

best overall operational effectiveness.

Whether customers opt for a scheduled,

contracted relationship or a pay-as-you-go

model, Husky provides access to experts

through a complete asset management

program comprised of a diverse range of

products and services.

Pro-Act

Tailored specifically for the injection mold-

ing industry, Pro-Act™ is Husky’s premier

proactive maintenance solution that offers

flexible programs to improve asset avail-

ability and performance.

Advisory services

Access Husky’s Service and Support

network to gain in-depth knowledge,

consulting and assessment expertise

throughout all levels of the production

process—from equipment level through to

plant level.

Hot runner maintenance

Husky maintenance services provide a

cost-effective solution to ensure optimized

hot runner performance. Services range

from melt channel cleaning to a complete

overhaul—all components are inspected

and those that do not meet original specifi-

cations are replaced.

Mold care

Husky refurbishment services provide a

cost-effective and thorough maintenance

solution to ensure improved productivity,

uptime and longer tool life.

Training

Husky provides comprehensive technical

training programs to support over 25 years

of equipment design. Husky certified train-

ers offer practical courses on a variety of

subjects and work with customers to devel-

op customized programs and schedules to

meet specific requirements.

Productivity and process monitoring

Applicable to both Husky and non-Husky

machines, our flexible monitoring systems

help to improve part quality and increase

output while our software solutions enable

real-time data collection for multiple injec-

tion molding systems.

Product upgrades

Husky works with customers to help mod-

ernize existing equipment to improve

productivity, reliability and functionality.

Spare parts

Husky supports an extensive global parts

and distribution network with the best

availability in the industry.

Third party services

Through our global network of contacts,

Husky is able to assist customers by coor-

dinating the sourcing and delivery of

complete turnkey systems that are opti-

mized for productivity.

Husky Services

Made from chlorine-free bleached pulp. Please recycle. 10-015 March 2010

Husky Injection Molding Systems

www.husky.ca

Head Office Canada • Tel. (905) 951 5000 • Fax (905) 951 5384

Asia China • Tel. (86) 21 5048 4800 • Fax (86) 21 5048 4900

Europe Luxembourg • Tel. (352) 52 11 51 • Fax (352) 52 60 10

® HUSKY, HUSKY KEEPING OUR CUSTOMERS IN THE LEAD & DESIGN, Polaris

and HyPET are registered trade-marks of Husky Injection Molding Systems

Ltd. in the United States and other countries, and may be used by certain

of its affiliated companies under License. Pro-Act, EcoBase, ServiceLink

and other HUSKY products or service names or logos referenced in these

materials are trade-marks of Husky Injection Molding Systems Ltd. and may

be used by certain of its affiliated companies under License.

© 2010 Husky Injection Molding Systems Ltd. All rights are reserved.

hypet preform systems (1)

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