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Light Weight Dairy Head Tooling

This document discusses strategies for reducing the weight of dairy containers through optimized head tooling design. It outlines the evolution of head tooling from round to ovalized and tri-ovalized designs, allowing reduction of container weights to as low as 56 grams for gallons and 40 grams for half gallons while maintaining quality. The document also notes additional design optimization services available from Uniloy to further light-weight dairy containers.

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jesrcontreras1976
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55 views4 pages

Light Weight Dairy Head Tooling

This document discusses strategies for reducing the weight of dairy containers through optimized head tooling design. It outlines the evolution of head tooling from round to ovalized and tri-ovalized designs, allowing reduction of container weights to as low as 56 grams for gallons and 40 grams for half gallons while maintaining quality. The document also notes additional design optimization services available from Uniloy to further light-weight dairy containers.

Uploaded by

jesrcontreras1976
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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LIGHT WEIGHT DAIRY HEAD TOOLING

Reduce the amount of resin you use while maintaining your dairy container
quality!
As you have made your containers more light weight to counteract the higher cost
of resin, Uniloy has continued to evolve our Head Tooling (die and mandrel) design
to maintain and improve your bottle quality and integrity. An optimized bottle is the
result of a well formed parison!

As molten plastic flows through the head it enters the die and mandrel where the
final parison shaping takes place. This orifice determines the diameter and wall
thickness of the parison. The pressure drop across this area is significant and
therefore the geometry of these two parts is critical. Slight changes to either the die
or the mandrel can cause drastic changes in the parison.

Die and mandrel design considerations include:

Container weight
Container width and depth
Type of neck finish
A Brief History of Dairy Head Tooling Design
The original dairy head tooling design was round and primarily for heavier
containers (i.e. 65 grams and above for gallons, 43 grams and above for half
gallons). When designing tooling at that time, we made adjustments to the die and
mandrel sizes based on the type of resin being used. For example, we found that
Union Carbide HDPE required smaller head tooling than Solvay or Phillips for the
same application.

A Round Die
Moving forward, we found that if ovalization was used in the die, while the mandrel
remained round, we could run multiple types of resin with the same die size.
Development of head tooling design was driven by customers desiring lighter
weight containers in an effort to reduce resin costs. However, it was very important
that the critical performance criteria of the bottle were met, such as:

Top Load Strength


Drop Impact Strength
Minimum Wall Thickness
Neck Dimensions
Etc.
Dairy Half Gallons
By adding strategically placed ovalization to the die component we were able to
maximize the container wall thicknesses in corner radii and 90 degrees from the
parting line. For dairy half gallons, we first developed an Ovalized die that would
work with a customers existing mandrel size. We continued to modify the
ovalization scheme for dairy half gallons until we discovered that a smaller die
worked the best. This Optimized design requires a new smaller mandrel as well.

An Ovalized Die

Dairy Gallons
A significant milestone in our development efforts came with the introduction of our
Tri-Ovalized design. At the heart of this improved design is the ovalization that
was added to three of the die quadrants. Along with this change we added flow
compensation scallops to the internal diameter of the die. These scallops relieve
die pressure which in turn allow parisons to drop more evenly. These changes to
the die allowed us to reduce the average container weight to as low as 60 grams
while maintaining and improving container integrity.

Our latest efforts to reduce container weight, without sacrificing container quality
has yielded our Tri-Optimized die design. This development builds upon what we
learned from the Tri-Ovalized design by modifying the exit angle of the die. This
change has allowed us to reduce the die diameter and maintain a sufficient die
swell. Although this change seems subtle, we are now able to successfully
produce a dairy gallon container as low as 56 grams!

A Tri-Ovalized Die with Scallops

Our Stable of Dairy Style Head Tooling


You will be able to reduce your overall container weight by a significant amount by
upgrading from Round tooling to either:

1st generation ovalized tooling (Ovalized for half gallons and Tri-Ovalized for
gallons),
Or:

2nd generation ovalized tooling (Optimized for half gallons or Tri-Optimized


for gallons)

Target
Preferred Die Part Nominal
Dairy Application Bottle Preferred Mand
Die Number Die Size
Weight

43 grams &
Half Gallon Round 898382 1.812 898383
up

40 42
Half Gallon Ovalized 70219-633 1.812 898383
grams

40 42
Half Gallon Optimized 70800-32 1.750 70800-33
grams
62 grams &
Gallon Round 80005-50 2.733 80005-51
up

60 62
Gallon Tri-Ovalized 80552-16 2.727 80522-215
grams

56 60 Tri-
Gallon 950543 2.625 950594
grams Optimized

Note: in some cases your existing mandrels will work with the new die designs;
otherwise a new set of mandrels will be required.
A Final Thought on Light-Weighting
The head tooling developments as detailed in this posting will certainly go a long
way towards helping you achieve your light weighting objectives. An additional step
is optimizing the design of your container. Our staff of Product and Mold Design
Engineers can be of great service to you. We will work with you from the
development of initial design criteria through to the realization of an improved,
production-worthy bottle design. Along the way, we can utilize our years of
experience and expertise, 3D printing capabilities, unit cavity / lab run facilities, and
extensive bottle testing lab / equipment, to get you there in an efficient and
effective manner.

Delivery, Sales and Service


We typically have any of the above referenced head tooling on hand and available
for immediate shipment. In cases where we are temporarily out of stock, please
allow 3 4 weeks for shipment.

Alternatively, if we are out of stock, we can manufacture components quickly using


pre-hardened stainless steel. The downside to this approach is that the material is
not as hard as standard hardened tool steel and therefore will wear prematurely.
This option, if taken, should be considered temporary.

For more information on this product offering or any other machine upgrade,
please contact your local Uniloy Parts Sales Representative. Trained Uniloy
Service Representatives are available to assist in the installation of these
components at your facility.

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