阿普拉(Alpla)岱纳(Dynapack)利士(Rex)合发(Hefa)中空吹塑瓶灌装/包装制品在线质量控制与检测

——产线中空吹塑吹气PE/PET/PP塑料瓶壁厚薄度100%在线制程质量检测 控制 原因 原理与技术方法（通过对产线一次或二次成型的中空吹塑/吹气PE/PET/PP塑料瓶进行100%在线重量检测来控制瓶壁厚薄度）——适用于盛装化妆品 沐浴露 洗发水 洗衣液 洗洁精 车用润滑机油 农药等化工制品 碳酸饮料 果汁 水 酒类 调味品 食用油等中空吹塑PE\PET塑料瓶在线重量称重检测，通过在线检测吹塑瓶的重量来检测控制吹塑瓶的瓶壁厚薄度（注：中空吹塑PE\PET塑料瓶最初从盛装车用润滑机油瓶开始要求在线重量检测，因为该类中空吹塑瓶要求较严格，后来逐步扩大到对盛装其它日用化工制品，食用品的PP\PC\PE\PET塑料瓶的在线重量检测。这体现了产品质量要求未来愈加严格的趋势）

 各类吹塑瓶（Various blowing bottle）

以下以PE机油瓶（用于盛装车用润滑机油的中空吹塑PE塑料瓶）为例，来阐述中空吹塑塑料瓶在线重量检测的目的、起因、方法、好处，以及我司中空吹塑塑料瓶在线重量检测业务开展情况（案例）

PE机油瓶检重机的使用目的【What's the purpose for PBBFEO（PE Blowing Bottle Filled with Engine Oil）】

对产线的PE机油瓶进行100%动态，快速，精准的重量检测，将不符合重量的PE机油瓶快速识别检测出来，且自动从产线剔除，防止流到下道工序，甚至出货。 Implementing a dynamic, fast, accurate 100% checking for weight of PBBFEOs, and then quickly check, identify, and remove some PBBFEOs not meeting the specified weight requirement out of the running belt, and stop them to flow to the next procedure, even to shipment. 

检测设备现场作业图（Picture for unit running on site）

PE机油瓶重量检测的起因(Whyneed to use the online checkweigher for PBBFEO)

某些PE机油瓶使用厂家（比如壳牌、美孚等厂商）对PE机油瓶的质量有要求。因为装好润滑油之后的机油瓶在运输与仓储过程中如因碰撞导致机油瓶开裂发生泄漏，会产生重大安全事故。相对来讲，重量轻的机油瓶其壁厚会薄些，破裂与漏油的的机率会更大些，由于以下因素。 Someenterprises using PBBFEOs (such as Shell, Mobil, Castrol etc.) have a strict quality requirement for PBBFEOs, there will be serious security implications during the transportation and storing of PBBFEOs, for example, due to leakage after being compacted heavy bombing caused hereby will hurt body, and even life for people. In a general, for the thickness of bottle wall, the thick ones will be easier to burst than thin ones. Reasons caused hereby as below】： 

1、由于PE机油瓶的产品构造与成型工艺（一步法吹塑成型）的原因，其重量（即瓶壁厚度）的稳定性远低于两步法（先注塑成型，再吹塑成型）的胶瓶； Due to PBBFEOs' structrue and forming processing(one-step blowing forming), their stability for weight(namely, thickness of bottle wall) will be far less than the ones with two-steps(namely, blowingforming after injecting forming).

 2、相对于水，机油的渗透性更强，瓶壁越薄，漏油的机率越大；同时温度越高，漏油的机率越大(比如导致瓶体膨胀，更易裂开，理论上讲)； Comparing to water, engine oil's osmosis to bottle wall will be stronger. The oil leak probability will be more if the bottle wall is thinner, as same as the higher temperature(In theory, bottle body expand caused hereby, therefore, easier to crack). 

3、装有机油的机油瓶在搬运使用过程中，如不小心掉地，产生撞击，瓶壁越薄，破裂漏油的机率越大；  Duo some reasons,PBBFEOs that being transported drop down, and impact to the ground, the PBBFEO with thinner bottle wall will be easier to leak. 所以对PE机油瓶的壁厚尺寸，也就是重量控制相当严格。为此，PE机油瓶使用企业要求其PE机油瓶供货厂家必须对其所供货的每个PE机油瓶进行产线100%制程质量控制。重量检测代替瓶壁厚度尺寸检测是较为理想的产线制程质量控制办法。 Therefore, implementing a 100% weight(namely, bottle wall size)checking for PBBFEOs is a MUST. Some enterprises using PBBFEOs require all of vendors that providing PBBFEOs to do a 100% IPQC for their ones as a contract term. 100% weight checking instead of 100% size checking for thickness of bottle wall is a suitable method for 100% IPQC. 

目前有些PE机油瓶生产厂家在对其机油瓶控制方面一般采用以下两种办法(Some quality control methods as below for suppliers making PBBFEOs )

1、抽检测试，机油瓶灌满水或油从规定的高度（比如2-2.5米）让其自由落地，这样重复10次（1角3边6面），检查有无破裂漏水或漏油。抽测频率：1次/2小时或1次/1小时不等； Sampling testing, the PBBFEOs will be filled with water or engineoil, and dropped down from the 2 to 2.5 meters, and then check whether the PBBFEO is leaked or not, and test 10 times(1 corner * 3 edges * 6 surfaces) like this. Sampling frequency: 1 time/2H or 1 time/1H or etc.  2、人工+电子称，采用人工将机油瓶放在电子称上称重。 Workers + Electronicscales, workers put every PBBFEO on the electronic scales, and check whether the weight displayed is within the specified weightrange or not. 

上述两种检测办法缺点如下(Defects as belowfor the above methods)： 

1、抽检测试：易漏检，无法从根本上防止重量轻的机油瓶包装出货； Sampling testing, easy to miss, can not completely prevent some light PBBFEOs from shipping.  

2、人工+电子称：效率低，易出错。同样无法从根本上防止重量轻的机油瓶包装出货。  Workers + Electronicscales, low efficiency, easy mistakeing. Its result is the same to the above 1st one.  

PE机油瓶重量检测根本解决办法-引进在线检重机

Fundamental solution(Funling's chekckweighers) for PBBFEOs' weight controlling） 

1、效率高（80-120件/分钟）；  High efficency(80-120 pcs/min). 

2、精度高（0.05-0.3g，具体根据PE机油瓶的规格与客户称重要求而定）；  High accuracy(0.05-0.3g,some changes depend on the reality such as PBBFEOs' spec. and clients' requirement).  

3、识别准（对不符合重量的机油瓶进行快速精准识别）；  Accurateidentification(identify some PBBFEOs not meeting the specified weight range.)  

4、自动剔除，将识别后不符合重量的机油瓶自动剔除出来，防止流到下到包装工序，最后到达客户或用户 中。 Automated removing, remove some PBBFEOs out of the running belt after being identified their weight are not meeting the specified weight range, completely prevent them from flowing to package position, even to hands of clients or users. 

总之，采用以100%检重的方式来检测PE机油瓶的壁厚尺寸是目前最为经济，有效的办法。  In a word, 100% onlineweight checking is a effective quality control method with low cost for PBBFEOs' wall thickness. 

我司目前该业务开展情况(Online checkweighers business overview for PBBFEOs)：

1、已有部分PE机油瓶设备生产商（比如东莞盛美等）已配套我们的检重设备； Someblowing machine manufacturers such as Dongguan Shengmei had matched their machine with our checkweighers. 2、已有部分PE机油瓶生产商【比如东莞合发包装（国内最大的PE机油瓶生产商，嘉实多、壳牌供货商.因产能不够大，未成为美孚供货商）、利士（新加坡丰隆集团子公司，壳牌、美孚供货商）、Dynapack Asia（壳牌、美孚供货商）,阿普拉(宝洁、联合利华、欧莱雅、拜尔斯道夫（妮维雅）、强生、可口可乐、BP、安利、箭牌世界五百强企业供货商)等】已经或准备引进我们的检重设备； Some PBBFEO manufactures had adopted or ready to adopt our checkweighers for their PBBFEOs' quality control, for example, Dongguan Hefa Package[A largest PBBFEO manufacturer in China, and one of vendors of Shell, Castrol, but not one of Mobil(due to short capacity), Dongguan Rex(one of subsidiaries of HongLeong Group, and one of vendors of Shell, Mobil), Dynapack Asia(one of vendors of Shell and Mobil)，Alpla(supplier of the world 500 strong enterprises(e.g.P&G,Unilever,L'Oreal,Beiersdorf AG(Nivea),J&J,Coca Cola,BP,Amway,Wrigley etc.)]. 3、用来装具有某些化学特性（比如低闪点、低挥发点、小分子、较强酸性或碱性等特性）的溶剂或液体的吹塑瓶，这些瓶子的壁厚尺寸也需要按PE机油瓶的质量要求，对其进行过程控制。 Some blowing bottle filled with solvent or liquid with certain chemical features(e.g. low point of flammability, low volatile point, consisting of micromolecules and stronger acidity or alkalinity etc.), their wall thickness need to be controlled like PBBFEOs. 

PE机油瓶生产企业引进产线检重机设备将产生以下经济效益(economic benefit caused hereby as below) 

1、降低人工成本；  Reducing the labor cost.  2、提高生产效率； Enhancing productivity.  3、提高产品整体质量水平； Improving total quality level. 4、维护企业声誉与品牌形象（减少客诉）；  Protecting enterprises' reputation and brand image(lower complaint from clients or users). 5、增强客户的合作信心（针对OEM厂商尤其是高端客户的OEM厂商）。  Increasingclients' confidence to cooperate with manufacturers(for OEMs, especial for some OEMs dealing with high end clients). 

以上陈述如有任何疑问，请随时与我联系(If any queries for the above， please don't hesitate to contact me.)

附

工业化大生产概述产线产品质量检验经历三个发展阶段（顺序依次如下）

1、最初的人工100%检查；

2、此后按抽样标准的随机抽检；

3、如今的产线100%自动化检测。

工业化大生产应具备三大特征

1、可重复性（大批量生产）；

2、可检验性（有效的大批量生产，保证大批量生产的产品符合质量要求，以降低不良品，减少浪费）；

3、可追溯性（产品信息从原材料生产到用户手中的每个环节均有记录，均可做到有据可查。一旦产品发生质量问题，在进行质量事故处理过程中，可节省时间，将不良影响降到最低）。

注：

1、毫无疑问，产线作业的自动化，无论在效率还是在精准性方面，都要远远高于人工操作；

2、只有产品产线逐步具备上述三大工业化特征的工厂企业才能在未来发展的更好，更有希望。