Blow molding production line layout: How much room do you really need?

By Slany Cheuang
Менеджер по техническим продажам, Leka Machine

When you are planning to buy a blow molding machine, the first question is usually about the price. The second question is usually about the speed. But there is a third question that often gets ignored until it is too late: “Will this actually fit in my factory?”

I have seen it happen many times. A customer buys a machine based on the dimensions listed in the catalog. They measure their floor, see that the machine fits, and think they are done. Then the equipment arrives. Suddenly, they realize there is no room for the chiller. The forklift cannot turn around to load the resin. Or worse, the maintenance technician cannot open the back door of the machine to change a filter.

Understanding space is not just about measuring the metal footprint of the machine. It is about visualizing the entire ecosystem of production.

What “space” really includes: not only the machine footprint

The dimensions you see on a spec sheet—like 5.6m × 2.9m × 3.5m for our FORMA H15L—are just the start. That is the physical size of the iron.

Real “production space” includes the invisible halo around the machine. This includes:

• Service clearance: You need at least 1 to 1.5 meters around the шкафу so doors can swing open and technicians can work.
• Heat dissipation: Hydraulic units and extruders generate heat. If they are crammed into a corner, your cooling costs go up and machine life goes down.
• Material logistics: How does the raw plastic get to the hopper? If you are using 25kg bags, a person needs to stand there. If you are using big bags (super sacks), a forklift needs to lift them high above the hopper.

Planning this early saves you money. It prevents you from having to knock down walls or move electrical drops later.

Typical users: OEM bottle factories vs brands bringing production in-house

Different types of companies view space differently.

If you are an established OEM packaging factory, you likely already produce bottles for big brands. You are probably trying to squeeze a new line into an existing, crowded facility. Your challenge is usually replacing an old, inefficient hydraulic machine with a newer one. You might be looking at our FORMA or AERO series to get more output per square meter.

If you are a Growth-Stage CPG Brand (like a cosmetic or food company), you might be bringing production in-house for the first time to control your supply chain. You might be renting a warehouse. For you, the risk is renting a building with a ceiling that is too low for the parison head, or a door that is too narrow for the machine delivery.

Key factors that decide how much space you need

Not all production lines are created equal. Here are the variables that change your layout.

Extrusion vs stretch blow molding

These two technologies have different footprints.

• Экструзионное выдувное формование (ЭВФ): Machines like our FORMA or TITAN series create a “parison” (a tube of molten plastic). These machines often generate “flash” (scrap plastic) at the top and bottom of the bottle. This means you need space right next to the machine for a deflashing unit and a scrap grinder to recycle that material immediately.
• Двухосное выдувное формование (ДВФ): Machines like our AQUA or BOTTLER series use preforms. There is no flash to trim, so you don’t need a grinder next to the machine. However, you need space for a preform dumper and loader, which can take up a surprisingly large amount of floor area.

Bottle size and output

The physical size of the product dictates the machine size. A machine making small 100ml cosmetic bottles (like the BOTTLER series) is compact.

But if you are making 30L industrial jerry cans, you need the TITAN series. These machines are tall and heavy. A TITAN H30L weighs 28.5 tons and is nearly 3 meters tall. You cannot just put this anywhere; you need a reinforced concrete floor and a high ceiling clearance for the mold clamping mechanism.

Utility equipment you can’t ignore

This is the biggest “space eater” that people forget. Your выдувная машина is useless without utilities. You need dedicated space for:

• High-pressure air compressor: Especially for SBM, which needs 30-40 bar pressure. These are loud and hot. Ideally, they go in a separate compressor room.
• Chiller: This cools the mold. It needs good airflow. If you put it indoors, you need excellent ventilation.
• Air Dryer: To keep moisture out of the pneumatic system.

Safety and people flow

Never block your exits. In your layout, you must mark out walkways (usually yellow lines on the floor). Ensure a forklift carrying a finished pallet of bottles can drive past the machine without hitting the operator panel.

Typical layout of a blow molding production cell

When we design a layout at Leka Machine, we divide the “cell” into four zones.

1. Core production zone
This is where the magic happens. It houses the выдувная машина and the HMI (Human Machine Interface). The operator stands here. We ensure there is room for a “mold change cart” to roll in and out, which is crucial for reducing downtime during product switches.

2. Upstream material flow
This is the feeding zone. For EBM, this includes the resin mixer, color doser, and auto-loader. For SBM, it is the preform hopper. This area creates dust, so it’s good to keep it slightly separated from the packing area if possible.

3. Downstream handling
Как только бутылка покидает форму, where does it go?

• Cooling conveyor: Fresh bottles are warm and soft. They need time to cool down before packing.
• Leak Tester: Every качество line needs one.
• Упаковка: This takes the most space. Whether it is manual packing tables or an automatic palletizer, you need room for stacks of cardboard boxes and wooden pallets.

4. Utility and service area
This is usually located behind the machine. It houses the electrical cabinets, water manifolds, and hydraulic pumps.

Example space plans for common blow molding projects

To give you a rough idea, here are two common scenarios.

Compact HDPE extrusion blow molding line

• Application: 1L to 5L detergent or chemical bottles.
• Machine: FORMA Series (e.g., FORMA H5L).
• Footprint: The machine is about 3.1m × 2.2m.
• Total Room Needed: You likely need a space of about 8m × 6m (48 sqm) for the whole cell. This allows for the scrap grinder, a conveyor belt, a leak tester, and a table for a worker to pack bottles into boxes.

PET stretch blow molding line

• Application: 500 мл бутылки с водой or beverage bottles.
• Machine: AQUA Series (e.g., AQUA E600M).
• Footprint: While the machine might be compact, the downstream is long.
• Total Room Needed: You are looking at a longer, thinner layout. Maybe 12m × 5m. Why? Because high-speed production (like 10,000+ bottles per hour) requires long air conveyors to buffer the bottles before they hit the labeler or packer.

How to estimate your own factory space

Do not guess. Follow this simple method before you ask for a quote.

1. Measure your “usable” floor: Ignore the corners filled with junk. What is the clean rectangle you have available?
2. Check the ceiling height: Measure to the lowest point (sprinklers, beams, lights). Our TITAN machines can be over 3.5 meters tall, and you need clearance above that for the hopper loader.
3. Identify the doors: Can a truck back up to the door? The machine is usually shipped in one or two large pieces.
4. Locate utilities: Where is the water pipe coming from? Where is the main electrical breaker?

How Leka Machine supports you

At Leka Machine, we don’t just sell you the crate and wish you luck. We help you plan the floor.

When you контакт us, we will ask for a simple drawing of your factory. It doesn’t have to be an architect’s blueprint—a hand sketch with dimensions works. We will then take our machine models (whether it is the versatile FORMA, the high-speed AERO, or the heavy-duty TITAN) and place them into your drawing.

We will add the conveyors, the scrap grinders, and the chillers to show you exactly how the flow will work. We can even help you plan for “Phase 2″—leaving empty space now so you can easily add a second machine next year without moving the first one.

If you are unsure if a machine will fit, just ask. Send me your bottle dimensions and your floor plan, and let’s figure it out together.

Would you like me to create a customized floor plan layout for your specific factory space?