FORMA plus series Fully Auto matic Extrusion blow molding machine
Case 1 and Video:
To Russia Order: LEKA FORMA Plus Fully Automatic Blow Molding Machine
The Challenge: Extreme Lightweighting of a 12L Jerry Can
A client from Russia recently ordered an equipment setup to produce 12L Jerry Cans. Their requirements were exceptionally clear and challenging: a daily output of 6,000 units, with each container weighing no more than 320 grams.
In the extrusion blow molding industry, this is not just a test of speed; it is a battle of parison control precision. Without perfect wall-thickness distribution, such a lightweight container would easily collapse during stacking tests.
To overcome this, I customized the FORMA Plus solution for them. We utilized a Hybrid design: the clamping mechanism remains hydraulic for maximum force, while all other movements are fully electric to ensure precision and efficiency.
Why Choose the FORMA Plus?
- 30% Energy Savings: The all-electric drive components significantly reduce unit energy consumption compared to traditional hydraulic machines.
- 25% Output Increase: As a high-speed model, it optimizes cycle times to comfortably meet the 6,000 unit-per-day target.
- Precision Wall-Thickness Control: Equipped with a MOOG 200-point parison controller, we achieved an ultra-thin wall while maintaining the stacking strength required for heavy-duty jerry cans.
Technical Specifications & Customized Configurations
To maximize automation and profitability (TCO), the client opted for the following advanced configurations:
| Category | Technical Details |
|---|---|
| Power & Control | Hybrid Clamping (Hydraulic) + Full Electric movement; MOOG 200-point Parison Control System. |
| Advanced Cooling | Post-mold cooling, neck cooling, and handle-setting cooling functions. |
| Automation | Integrated auto-deflashing and robotic arm for automatic take-out. |
| Turn-Key Integration | Full-line automation: Constant speed conveyor, auto-material loading, waste recycling system, leak tester, and online weighing machine. |
Ultimately, the client was highly satisfied with the machine's stability and performance. If you are looking for a solution that balances lightweighting with high-strength production, please visit our Extrusion Blow Molding Machine page for more details.
FORMA plus series Fully Auto matic Extrusion blow molding machine
Case2 and Video
To Vietnam Order: LEKA FORMA 3-Layer Co-Extrusion High-Speed Line
The Challenge: High Output with Material Cost Control
A manufacturing client from Vietnam approached me with a common headache. They needed to produce high volumes of plastic bottles—12,000 units per day—but the rising cost of raw materials was eating into their profits.
They needed a way to use cheaper recycled materials without making the bottles look "cheap" or losing strength. They also faced a labor shortage, so they couldn't afford to have workers manually trimming flash or packing bottles.
To solve this, I designed a configuration based on our FORMA Plus Series. We utilized 3-Layer Co-Extrusion technology (Screw sizes 90mm+65mm+30mm). This allows the client to use recycled material for the middle layer while keeping the outer layer smooth and colorful with virgin material.
Why Choose This 4-Head Configuration?
- Massive Output: By using a 4 Die Head setup, the machine produces four bottles every single cycle. This easily hits the target of 12,000 bottles per day.
- Material Savings (ROI): The "90+65+30" screw configuration is the magic here. You can hide up to 60-70% recycled regrind in the middle layer. This significantly lowers your material cost per bottle.
- Zero Labor Waste: From the moment the plastic melts to when the bottle is boxed, no human hands touch it. The machine handles Auto Deflashing, Leak Detection, and Packaging automatically.
Technical Specifications & Customized Configurations
For this Vietnam project, we focused on "Total Automation" to reduce their long-term operating costs (TCO). Here is the exact setup:
| Category | Technical Details |
|---|---|
| Production Capacity | 4 Die Head configuration achieving 12,000 bottles/day output. |
| Co-Extrusion System | 3-Layer Extrusion (90mm + 65mm + 30mm screws). Ideal for Sandwich (ABA) or multi-layer structures to utilize recycled materials. |
| Post-Cooling | Dedicated Post-Cooling station to speed up cycle time and ensure dimensional stability of the bottles. |
| Full Automation | Robot arm bottle handling for precise takeout, coupled with Auto Deflashing and Auto Material Recycling. |
| Quality Control | Integrated Auto Leak Detection and Auto Packaging system to ensure 100% qualified products reach the box. |
The client in Vietnam is now running this line with minimal staff while saving heavily on raw plastic costs. If you need to upgrade your production capacity or want to start using co-extrusion to save money, check out our Extrusion Blow Molding Machine page.