85mm Neck, large diameter, 60g weight, wide mouth, PET food-grade plastic preform for shower gel bottles, blow molding preform tube

FEATURES

• Ansix Tech operates four production facilities across China and Vietnam with a total of 260 injection molding machines, ranging from 30 tons to 2,800 tons, providing substantial production capacity for high-volume preform orders. For the 85mm neck, 60g preform, typical delivery lead times are as follows: sample preforms within 10–15 days for mold trials; standard production orders 20–25 days from PO confirmation; and expedited production 15 days for urgent requirements. The 96-cavity mold configuration allows each injection cycle to produce 96 preforms simultaneously, significantly boosting per-hour output.

  
  

• Mold Description
  Product Materials:	PET PETG
  Mold Material:	S136ESR
  Number of Cavities:	12
  Glue Feeding Method:	Hot runner
  Cooling Method:	Water cooling
  Molding Cycle	22.5s

  
  
  

• 
• The mold manufacturing process and product material selection
  

  Quality Assurance

  Quality control follows international standards with measurable acceptance limits: preform weight control within ±0.2–0.5% per cavity; moisture after drying maintained below 50 ppm (typically 20–40 ppm) to prevent hydrolysis; intrinsic viscosity (IV) drift tracked within ±0.02 dL/g for stable stretch-blow behavior; and acetaldehyde content maintained below 10 ppm for water-grade applications. Each preform undergoes visual inspection under consistent lighting to detect gate blush, splay, black specs, bubbles, and short shots. Polarized-light inspection checks stress/birefringence to detect over-packing or uneven cooling. Dimensional verification uses neck finish gauges for thread OD/ID, tamper band, and sealing land dimensions with Cp/Cpk monitoring. A full-scale prototype insert is made using high-speed machining and additive-manufactured cooling channels, producing actual preforms that undergo stretch blow molding testing for top-load strength, leakage, and visual clarity before final mold approval.

• Most Competitive Cost Control

  Cost optimization is achieved through several strategies: high-cavity (96-cavity) mold tooling to maximize output per machine hour, reducing unit production costs; optimized cooling system design to shorten cycle times by improving cooling efficiency; weight optimization to specify only necessary PET material without over-specifying; DFM (Design for Manufacturability) analysis before steel cutting to identify potential issues early, eliminating costly rework cycles; and in-house manufacturing with four vertically integrated production facilities to eliminate middleman markup. A 1g reduction in preform weight across millions of units delivers substantial cumulative material savings. Simulation-driven optimization helps simplify geometry, improve gate and runner design, enhance cooling efficiency, and reduce resin content, all of which lower tooling, scrap, and production costs.

   

  Core Value: Mold Manufacturing & Injection Molding Material Selection, Smart Manufacturing Integration, and Process Quality Assurance for 85mm Neck, Large Diameter, 60g Weight, Wide Mouth PET Food-Grade Plastic Preform

  Material Selection for Mold Manufacturing and Injection Molding

  Mold material selection directly impacts mold lifespan, part quality, and production cost. For the 85mm neck, 60g PET preform mold, Ansix Tech employs a strategic selection framework. The mold base uses pre-hardened P20 steel for structural integrity and cost efficiency. Core and cavity inserts requiring high wear resistance and thermal conductivity use premium tool steels: S136 stainless steel for corrosion resistance — essential for humid molding environments and PET processing; H13 hot work steel for high-temperature applications, ensuring thermal fatigue resistance; 2343/2344 chromium hot work steels for long-run high-cavity production; 8407 premium-grade H13 variant for extended mold life under continuous operation; SKD11/SKD61/DC53 for applications requiring superior wear resistance and toughness; M340/4Cr13/9Cr18 stainless grades for food-grade applications demanding corrosion protection; NAK80 pre-hardened steel for applications requiring excellent mirror polishability and dimensional stability. For high-cavity PET preform molds (e.g., 96 cavities), each cavity is machined to extremely high precision levels, achieving preform wall thickness deviation less than 0.05mm and weight deviation less than 0.3g across all cavities. These materials ensure mold lifespans of 500,000 shots for glass-filled PET applications and up to 1,000,000+ shots for standard PET.

   

  Injection molding material selection centers on PET resin properties. Ansix Tech recommends bottle-grade PET resin with intrinsic viscosity (IV) of 0.80 dL/g — the optimal balance between processability and final bottle strength. Key resin specifications include: IV 0.78–0.85 dL/g; moisture content <0.005% (50 ppm max) before processing; acetaldehyde content <3 ppm for sensitive applications; and crystallinity <30% in preform for optimal blowability. Compatible materials for special applications include PETG for enhanced clarity and chemical resistance, rPET (recycled PET) for sustainable packaging options with IV monitoring to maintain performance, and glass-fiber-reinforced PET for structural applications requiring increased stiffness.

   

  Smart Manufacturing Integration and Efficiency Improvement

  Ansix Tech implements Industry 4.0 intelligent manufacturing across its four production facilities. All injection molding machines are networked with MES (Manufacturing Execution System) that locks critical molding parameters — temperature, pressure, velocity, and cooling time — to engineer-only access, eliminating unauthorized adjustments. Real-time process monitoring across all 260 machines (30–2,800 tons clamp force range) includes ultrasonic wall thickness sensors providing live feedback on preform wall thickness distribution, with automatic compensation adjustments to injection and packing parameters. Cavity pressure and temperature sensors in the mold provide closed-loop control for consistent filling and cooling. Automated guided vehicles (AGVs) handle preform transfer from molding to packaging lines, reducing manual handling and contamination risk.

   

  For the 85mm neck, 60g wide mouth preform, Ansix Tech can run both conventional injection molding and injection stretch blow molding (ISBM) equipment. Conformal cooling technology allows the mold to run significantly faster in existing injection molding machines while improving splitline appearance and ovality, requiring less than half the coolant flow of typical preform molds. Advanced hot runner systems with multiple control zones ensure temperature control along the entire PET pathway inside the hot runner, resulting in higher production quality and minimized stress on the material.

   

  Digital twin simulation and process optimization use advanced CAE tools like Moldex3D for comprehensive mold flow analysis that simulates filling patterns, identifies weld lines, predicts air traps, and optimizes gate locations before steel cutting. For high-cavity molds, a five-layer runner structure ensures melt flows uniformly into every cavity, achieving consistent product cooling across all 96 cavities.

   

  Efficiency gains are substantial: 96-cavity mold configuration produces 96 preforms per injection cycle; conformal cooling reduces cycle time by 15–25%; automated quality inspection reduces post-molding handling time; and MES-driven parameter standardization reduces setup time for repeat orders.

   

  Process Quality Assurance

  Quality assurance begins at the design stage. Ansix Tech provides comprehensive DFM (Design for Manufacturability) reports before cutting steel, addressing wall thickness balance for uniform filling and cooling without sink marks, gate location optimization for balanced cavity filling and minimal gate vestige, draft angles for clean part ejection without scratches, shut-off design for flash-free sealing, and cooling layout optimization for uniform solidification.

   

  During production, quality control follows rigorous protocols. Material preparation includes drying PET pellets for 4–6 hours at 160–165°C, achieving a dew point of -40°C, with Karl Fischer moisture verification. Injection molding parameters are locked in MES, with real-time monitoring and automated reject ejection for off-spec preforms. Post-molding quality verification includes weight verification (±0.2–0.5% tolerance), dimensional inspection using CMM for neck finish geometry and length, IV testing via solution viscometry to confirm no hydrolysis, acetaldehyde testing via GC for taste-sensitive applications, birefringence stress inspection under polarized light, and visual inspection for gate blush and splay.

   

  Process capability targets are measurable: preform weight Cpk ≥ 1.33 across all cavities; neck finish dimension Cp/Cpk ≥ 1.33 for leak-proof sealing; and wall thickness distribution consistent across all 85mm neck preforms.

   

  Traceability and documentation include individual cavity traceability — each preform traceable back to specific mold cavity for root cause analysis; material lot traceability; and full dimensional reports with CMM data included with each shipment. Every mold undergoes full dimensional reporting before shipment with CPK ≥ 1.33 on critical dimensions.

   

  Comprehensive Manufacturing Solution for 85mm Neck, Large Diameter, 60g Weight, Wide Mouth PET Food-Grade Plastic Preform

  Section 1: “Hard Power” Foundation — Equipment Infrastructure That Builds Customer Confidence

  Injection molding and mold manufacturing for large-diameter PET preforms demands world-class equipment to achieve the precision, consistency, and volume required for high-speed consumer packaging production.

   

  Mold Machining Equipment

  Ansix Tech’s mold manufacturing center is equipped with 5-axis high-speed machining centers capable of machining complex curved surfaces to 0.002mm accuracy. This precision directly translates to customer value: smooth, burr-free splitlines on the preform neck finish, eliminating secondary finishing operations and ensuring clean sealing surfaces for capping. The 5-axis capability also enables machining of conformal cooling channels following the contoured shape of the preform cavity, dramatically improving cooling efficiency compared to conventional straight-drilled lines.

   

  For fine-feature machining, slow wire EDM (electrical discharge machining) with 0.03mm fine-hole capability enables the creation of detailed features like venting slots and narrow grooves without causing thin-wall deformation. This ensures proper venting to eliminate trapped air during injection, preventing burn marks on the preform surface.

   

  For high-cavity PET preform molds (96 cavities and above), ultra-precision machining ensures each cavity is machined to consistent tolerances. Wall thickness deviation across cavities is maintained below 0.05mm and weight deviation below 0.3g — meaning every preform from any cavity blows into an identical bottle, eliminating reject sorting and downstream filling issues.

   

  Injection Molding Machine Fleet

  Ansix Tech operates 260 injection molding machines with clamping forces ranging from 30 tons to 2,800 tons across four production facilities in China and Vietnam. The 30–500 ton range is dedicated to precision small parts; the 500–1,500 ton mid-range is optimized for PET preform production; and the 1,500–2,800 ton high-tonnage range handles large-format preforms and heavy parts.

   

  For the 85mm neck, 60g PET preform, All-electric servo-driven injection molding machines deliver repeatability precision of ±0.1%. This means every shot cycles identically to the previous one — every preform is molded to the same weight, dimensions, and wall thickness. Batch-to-batch consistency is guaranteed, enabling customers to run blow molding lines without stopping to adjust for preform variations.

   

  Inspection and Measurement Equipment

  Ansix Tech’s quality laboratory is equipped with coordinate measuring machines (CMM) capable of measuring complex 3D geometries to 0.001mm resolution. Optical inspection systems provide automated dimensional verification at production speeds. Each mold undergoes full dimensional reporting before shipment, with key dimensions validated to Cp/Cpk ≥ 1.33 — a statistical guarantee that the process is capable of producing parts within specifications consistently, not just occasionally.

   

  Section 2: Core Mold Manufacturing Competitiveness — Customer Value in Concrete Metrics

  Customers evaluating preform mold suppliers have four primary concerns: lifespan, precision, delivery speed, and repair cost. Ansix Tech addresses each with measurable commitments.

   

  Mold Lifespan Commitment

  Material Application Guaranteed Shots

  P20 pre-hardened Mold base, standard inserts 500,000+

  S136 stainless Food-grade, corrosive environments 1,000,000+

  H13/2344/8407 High-temperature, wear-intensive 1,000,000+

  NAK80 High-gloss, transparent parts 500,000+

  DC53 Extreme wear applications 800,000+

  Customer value: A 1,000,000-shot mold means customers can run continuous production for years without mold replacement. Each shot produces 96 preforms simultaneously — mold replacement downtime costs are eliminated.

   

  Attainable Tolerances

  Conventional structural components are held to ±0.05mm tolerance. For critical features like the 85mm neck thread finish and sealing lands, precision preform applications require tolerances up to ±0.005mm on CTQ features. Ansix Tech provides material certification reports and heat treatment curves with every mold — full transparency about what is built into the tool.

   

  Mold Type Capabilities

  Hot runner systems: The preferred approach for PET preforms eliminates runner scrap entirely, reducing material waste and eliminating the cost of regrinding and reprocessing. Modern hot runners feature multiple control zones ensuring temperature control along the entire PET pathway from runner inlet to cavities — delivering higher production quality and minimizing material stress.

   

  High-cavity molds: For high-volume shower gel bottle production, 96-cavity molds produce 96 preforms per injection cycle — maximizing output per square meter and per machine hour. The key challenge — achieving flow balance across 96 cavities — is solved through a five-layer runner structure design that ensures PET melt flows uniformly into every cavity, enabling consistent product quality across all cavities.

   

  Gate and Runner Strategy Optimization

  Ansix Tech uses mold flow analysis to predict weld line and air trap locations before steel cutting, optimizing gate count and location to ensure balanced filling across all 96 cavities. For the 85mm neck preform, gate location is strategically placed below the neck finish to minimize cosmetic impact on the final bottle.

   

  Delivery Time Standards

  Mold Type Standard Lead Time Expedited Lead Time

  Single-cavity prototype 10–15 days N/A

  8–24 cavity standard 20–25 days 15 days

  32–48 cavity production 25–35 days 20 days

  72–96 cavity high-volume 35–45 days 25 days

  Even under expedited schedules, validation steps — DFM review, mold flow analysis, T0 sampling — are never skipped. Cutting corners on validation only pushes problems to production, costing far more than a few extra days upfront.

   

  Section 3: Injection Molding Process Control — Eliminating Customer Quality Anxiety

  Customers fear quality defects that disrupt filling lines: shrinkage voids that create weak bottle spots; flash requiring expensive manual deflashing; inconsistent dimensions causing capping failures; and batch-to-batch color variations affecting brand presentation.

   

  Process Standardization

  All injection molding machines are networked to an MES (Manufacturing Execution System) that locks critical parameters — barrel zone temperatures, injection pressure, holding pressure, injection velocity, cooling time — to engineer-only access. Every batch begins with a first-piece inspection (dimensions and weight) and ends with a last-piece comparison (ensuring no process drift). No operator can “tune” the machine to solve a problem in ways that create new problems downstream.

   

  Dimensional Stability Control

  Mold temperature controllers with zone-specific control keep core and cavity temperatures within 2°C difference, reducing warpage and shrinkage variation. For the 85mm neck, 60g preform, ultrasonic wall thickness sensors provide real-time data on wall thickness distribution during injection. Automatic compensation adjustments to packing pressure ensure consistent wall thickness across all 96 cavities. Real-world performance data demonstrates that on similar container preform projects, critical dimension (e.g., neck OD) across three batches over seven days stays within 0.02mm of nominal.

   

  Appearance Quality Grades

  PET preform quality is quantified by measurable parameters: cavity weight uniformity within ±0.2–0.5% across all 96 cavities ensures consistent bottle weight after blow molding; preform clarity with zero bubbles or flow lines ensures final bottles have glass-like transparency essential for premium shower gel packaging; birefringence stress levels controlled via optimized cooling minimize haze in blow-molded bottles.

   

  Special Material Processing Capabilities

  Ansix Tech has production experience with a comprehensive range of engineering resins: PC/ABS for durable cosmetic housings; PC for clear, impact-resistant parts; PPS + 40% GF for high-temperature, chemical-resistant applications; PEEK for extreme high-temperature (up to 250°C continuous use) and chemical resistance applications; PTFE/PFA for chemical-resistant, non-stick applications; PA6 + 30% GF for strength and stiffness; PBT for electrical insulation; PEI (Ultem) for structural integrity in humid environments with excellent flame retardance; LCP for high-temperature, thin-wall molding; and liquid silicone rubber (LSR) for soft-touch or sealing components. For applications requiring flame resistance, UL94 V-0 rated materials are available. For outdoor-exposed bottles, UV-resistant formulations guarantee 3,000 hours without color change.

   

  Section 4: Full-Service Process — Reducing Customer Management Cost

  Many manufacturers treat mold delivery as the finish line. Ansix Tech recognizes that delivering a mold is the beginning of a partnership.

   

  Early-Stage DFM (Design for Manufacturability) Reports

  Before a single gram of steel is cut, Ansix Tech provides a comprehensive DFM report that analyzes the customer’s product design for manufacturability. The report addresses: draft angle recommendations — ensuring parts eject cleanly without scratching the preform surface; wall thickness optimization — preventing sink marks and voids in thick sections while maintaining structural integrity; gate location and size — positioning for balanced filling and minimal gate vestige; ejector pin location and allowable witness marks — avoiding cosmetic surfaces on the final bottle; part shrinkage compensation — ensuring dimensions meet specifications after cooling; and cooling system layout — ensuring uniform solidification and minimizing cycle time.

   

  The DFM report is delivered before mold construction begins, eliminating the risk of discovering manufacturing problems after steel has been cut and thousands of dollars spent.

   

  Mold Sampling and T0–T3 Validation

  Mold development follows a structured validation protocol:

   

  T0 (First shot): First samples produced, evaluated against CTQ dimensions

   

  T1 (First adjustment): Mold adjusted based on T0 results, re-sampled

   

  T2 (Second adjustment): Iterative improvements

   

  T3 (Validation complete): Pre-production validation complete, ready for mass production

   

  Each trial produces actual preforms, accompanied by a detailed improvement report documenting changes made and results achieved. Ansix Tech can quickly exchange mold inserts to test different gate designs, cooling configurations, or material grades — without rebuilding the entire mold from scratch.

   

  Low-Volume Pre-Production Validation

  Before authorizing full-scale production, Ansix Tech offers 100–500 shots of pre-production run to verify yield rate, measure CPK on all CTQ dimensions, and confirm process stability. If issues are detected, they are resolved before mass production begins — not after millions of defective parts have been produced.

   

  Maintenance and Spare Parts Support

  Each mold is delivered with a complete set of replacement wear parts (ejector pins, core inserts, guide bushings) to minimize downtime when maintenance is needed. Every 200,000 shots, Ansix Tech recommends a mold maintenance service. Lifetime repairs are provided at material cost only — not as a profit center.

   

  Section 5: Differentiated Customer Commitments

  Rather than vague claims of being “the best,” Ansix Tech provides specific commitments addressing common industry complaints.

   

  Complaint: “Molds constantly need repair, disrupting production schedules.”

  Commitment: Each mold undergoes 2,000-cycle proof-of-life run before delivery, generating a wear progression report documenting how surfaces and edges perform over repeated cycles. Three-year structural warranty on the mold (excludes routine consumables) provides financial protection.

   

  Complaint: “Flash requires manual trimming — expensive secondary operation.”

  Commitment: Ansix Tech machines parting surfaces to 0.005mm fit precision. Self-locking clamp force compensation ensures flash is consistently maintained below 0.03mm across all production batches, eliminating manual deflashing.

   

  Complaint: “Dimensional results change every time we run a batch.”

  Commitment: Real-time process control via ultrasonic wall thickness sensors detects fluctuations and applies automatic compensation to holding pressure. In-mold pressure and temperature sensors provide closed-loop control of every shot. For applications requiring the highest consistency, mold pressure sensors provide continuous feedback.

   

  Complaint: “Mold repair takes weeks — production stops.”

  Commitment: In-house electrode manufacturing and EDM departments eliminate external dependency for repairs. Standard repairs (localized welding, insert replacement) are completed within 24 hours of returning the mold to Ansix Tech’s facility.

   

  Conclusion: A Mold as a Printing Press, Not a Piece of Metal

  At Ansix Tech, a mold is designed from the perspective of production line efficiency, cooling balance, venting strategy, and ejection reliability — ensuring that by the time it reaches the production floor, it requires minimal debugging, produces minimal flash, and delivers maximum lifespan. Customers are invited to experience a DFM report walk-through of an existing product, seeing in advance how weld lines, air traps, shrinkage risks, and dimensional control challenges are solved proactively.

   

  Customer value translation:

   

  Five-layer runner design → Preforms from every cavity have identical weight and wall thickness → No rejects in blow molding line

   

  Conformal cooling → 15–25% faster cycle times → More preforms produced per day for same investment

   

  0.005mm fit precision → No flash → Eliminates manual deflashing cost

   

  Three-year structural warranty → No unplanned mold repair cost — predictable maintenance expense

   

  Standard Preform Weights for PET Preforms

  For the 85mm neck specification, 60g represents a specific point within a broader standard range. The following are standard weight options for PET preforms from industry references:

   

  85mm Neck PET Preform Standard Weights (from industry data):

   

  Industry catalogs list 85mm neck PET preforms available in standard weights including 40g, 45g, 50g, 55g, 68g among the options. Some suppliers also offer custom weights from 12g to 180g for wide neck diameters.

   

  Broader PET preform market references show other standard weights: 58mm neck preforms in 23g; 68mm preforms in 25g, 28g, 32g, 35g, 38g, 30g, 40g; 95mm neck preforms in 40g, 45g, 50g, 52g, 55g, 58g, 60g, 65g, 68g, 75g, 78g, 90g, 100g; and 118mm preforms in 80g, 85g, 90g, 100g, 110g, 120g, 140g, 150g, 160g, 180g, 200g, 215g.

   

  For the specific 85mm neck, 60g weight, PAVICO’s catalog confirms PET preform 85mm 56g as a standard offering, indicating the 60g weight falls within the standard range for this neck size.

   

  Preform Weight (g) Typical Application Blown Bottle Volume (approx.)

  40g–50g Light-duty jars, travel sizes 100–250ml

  55g–60g Standard shower gel bottles 250–500ml

  68g–75g Large bottles, thick-walled containers 500–750ml

  80g–100g Heavy-duty or extra-large containers 750–1000ml+

  The 60g weight represents the mid-to-heavy range for 85mm neck preforms, ideally suited for standard shower gel bottles requiring good wall thickness and structural strength.

   

  Ansix Tech’s Customer Value Proposition

  Value Provided to Customers

  Ansix Tech provides end-to-end PET preform and mold manufacturing solutions with over 28 years of injection molding and mold making experience. From design prototype confirmation through to mass production and assembly validation, Ansix Tech has a proven track record of delivering reliable, high-performance PET preforms for global customers across cosmetics, personal care, and food packaging sectors.

   

  Problems Solved for Customers

  Inconsistent preform weight and dimensions: By operating 260 injection molding machines from 30 to 2,800 tons with MES-controlled process parameters, every preform is molded to identical specifications — eliminating adjustment of blow molding lines between batches.

   

  High scrap rates in blow molding: Preform quality is directly linked to blow molding success. Through IV control (±0.02 dL/g drift), weight control (±0.2–0.5%), and moisture control (<50 ppm), downstream blow molding issues like pearlescence, uneven wall thickness, and burst failures are virtually eliminated.

   

  Regulatory compliance risk: PET preforms are produced from virgin food-grade PET resin with full traceability, meeting global food contact standards including FDA and EU 10/2011. Material certification and test reports accompany every shipment.

   

  Production capacity constraints: With 260 injection molding machines across four facilities, Ansix Tech provides scalable production capacity for customers ranging from small startups to multinational brands. The ability to run high-cavity molds (96 cavities per shot) dramatically increases output per machine.

   

  Long lead times and supply chain risk: With four manufacturing sites in China and Vietnam, Ansix Tech provides geographic diversification and redundancy. Any single site can continue production if others experience disruption.

   

  Quality Validation Process

  Stage Activity Customer Benefit

  Design DFM report with mold flow analysis Issues identified before steel cutting

  Mold Build CMM full dimensional reporting Guarantee of mold build accuracy to specifications

  T0–T3 Sampling Multiple validation runs with documented adjustments Mature mold before production authorization

  Low-volume validation 100–500 shot pre-production run with CPK measurement Statistical confirmation of process stability

  Production SPC monitoring with per-cavity traceability Continuous quality visibility; root cause traceability

  Shipment Material certificates + dimensional reports + AA/IV test results Documentation for regulatory compliance and customer QA

  Cost Reduction Strategy

  Material cost reduction: Through weight optimization — specifying precisely the preform weight needed for the application without over-specifying, a 1g saving across millions of units delivers substantial cumulative savings. Through gate and runner design optimization — hot runner systems eliminate 100% of runner waste. Through regrind management — internal scrap recycling systems capture and reprocess edge trim and production waste, recovering material value.

   

  Process efficiency improvement: Through high-cavity mold design — more preforms per cycle reduces unit energy and labor cost. Through conformal cooling technology — shorter cycle times increase machine throughput. Through MES-driven process standardization — reduced setup time between orders and faster changeovers.

   

  Tooling cost optimization: Through DFM upfront — design reviews before mold construction eliminate costly rework cycles. Through in-house manufacturing — all mold components machined in Ansix Tech’s own facilities, eliminating external supplier markup.

   

  Production Capacity and Delivery Assurance

  With 260 injection molding machines ranging from 30 to 2,800 tons, Ansix Tech has the equipment diversity to handle any preform size from 12g to 180g. Four production sites in China and Vietnam provide redundancy — production can be redirected if any site experiences issues. In-house mold manufacturing eliminates external dependencies. Real-time MES dashboards provide customers with production status visibility. Standard lead times are 20–45 days depending on mold complexity, with expedited options available.

   

  Raw Material Selection for 85mm Neck, 60g PET Preform

  Primary Resin: Virgin PET (Polyethylene Terephthalate)

  PET is manufactured through chemical synthesis: ethylene glycol (EG) and terephthalic acid (PTA) undergo esterification to create PTA polyester prepolymer, which then undergoes polycondensation under high temperature and pressure to form long-chain PET polymer, resulting in PET resin pellets.

   

  Property Specification

  Material name Polyethylene Terephthalate (PET)

  Specific grade Bottle-grade virgin PET

  Intrinsic viscosity (IV) 0.78–0.85 dL/g (0.80 dL/g recommended for balance of processability and strength)

  Moisture content (pre-drying) <50 ppm (target 20–40 ppm)

  Acetaldehyde content <10 ppm for water-grade; <3 ppm for sensitive applications

  Density 1.33–1.39 g/cm³

  Melt temperature 250–280°C

  Glass transition temperature (Tg) ~75°C

  Crystallinity in preform <30% (to maintain blowability)

  Material Characteristics Relevant to Customer Value

  Excellent clarity: PET’s natural transparency provides glass-like bottle clarity — premium shower gel products appear high-end on retail shelves, and consumers can see product level and appearance before purchase.

   

  Pressure resistance and durability: PET withstands transportation and storage stresses — bottles do not deform or leak, reducing product loss and customer complaints.

   

  Recyclability: PET is fully recyclable (resin code #1) — supports brand sustainability goals and consumer recyclability expectations.

   

  Low acetaldehyde content: Maintained at <10 ppm for water-grade applications — ensures shower gels and cosmetics have no unwanted plastic odor that could negatively affect the consumer’s sensory experience.

   

  DFM and Mold Flow Analysis for 85mm Neck Preform

  Before any steel is cut, comprehensive mold flow analysis simulates filling patterns to identify potential issues: weld line locations predicting where material flow fronts meet; air trap positions; optimal gate placement; and cooling uniformity. DFM addresses wall thickness balance — uniform material distribution for uniform cooling and elimination of sink marks; draft angles for clean part ejection without scratching; and shrinkage compensation for precise final part dimensions. Simulation-driven optimization lowers cost and material usage — mold flow helps improve gate and runner design, enhance cooling efficiency, and reduce resin content, which all lower tooling, scrap, and production costs.

   

  Mold Design Priorities for High-Cavity Production

  The 96-cavity mold design prioritizes flow balance — ensuring melt flows uniformly into all cavities; cooling uniformity — eliminating hot spots and cold spots through conformal cooling; and precision alignment — using dual-cone positioning technology providing independent self-locking for each cavity, ensuring concentricity and eliminating “drift” over long production runs.

   

  Mold Manufacturing Challenges and Solutions for 85mm Neck Preform

  Challenge Solution Benefit

  Maintaining wall thickness consistency across 96 cavities Ultra-precision machining to <0.05mm deviation Every preform blows into identical bottle

  Achieving flow balance at 96 cavities Five-layer runner structure with smooth radius connections All cavities fill simultaneously with identical pressure

  Cooling uniformity across large mold base Conformal cooling channels machined via 5-axis CNC Uniform cooling reduces cycle time by 15–25%

  Preventing gate crystallinity Aggressive cooling in gate area with thermally insulated nozzle design Clear gate area with no haze or brittleness

  Mold alignment over millions of cycles Dual-cone self-locking positioning system No concentricity drift over mold lifetime

  Cooling System and Runner System Design

  The cooling system is designed for high-cavity production: conformal cooling channels follow the contoured shape of the preform cavity for uniform cooling across all 96 cavities. Water channels are strategically placed in gate area, thread splits, and core, designed for turbulent flow at minimum flow rates to maximize heat transfer efficiency. The hot runner system features a five-layer runner structure with smooth radius connections to reduce material shear and pressure drop, minimizing stress and improving melt uniformity. The new Flow+ generation of hot runners provides temperature control along the entire PET pathway inside the hot runner, resulting in higher production quality and minimizing stress on the material.

   

  Ejection System Design

  The ejection system uses self-locking dual-cone positioning technology for each cavity, providing independent alignment and ensuring concentricity. This eliminates drift over long production runs and ensures each preform ejects cleanly without damaging the 85mm neck finish.

   

  Injection Molding Challenges for 85mm Neck Preform

  IV degradation: PET’s hygroscopic nature requires drying to <50 ppm moisture before processing to prevent hydrolysis. Solution: Three-in-one equipment (feeding, drying, dehumidifying) with Karl Fischer moisture verification.

   

  Acetaldehyde generation: Excessive melt temperature or residence time generates acetaldehyde, causing odor. Solution: Optimized barrel temperature profile (280°C maximum) with minimized melt residence time.

   

  Gate crystallinity: Improper gate cooling creates crystallized haze. Solution: Thermally insulated gate design with aggressive gate area cooling.

   

  Uneven cooling and warpage: Non-uniform cooling causes ovality in wide mouth preforms. Solution: Conformal cooling channels with turbulent flow design.

   

  Cavity-to-cavity variation: High-cavity mold imbalance creates inconsistent preforms. Solution: Five-layer runner design with smooth radius connections.

   

  Injection Molding Process Optimization

  Drying optimization uses three-in-one equipment: 4–6 hours at 160–165°C, achieving dew point of -40°C and moisture <50 ppm. Melt temperature optimization sets barrel zones 1–5 at 260–280°C, with minimized residence time through optimized shot sizing. Injection parameters set injection speed at 100–150 mm/s to reduce melt viscosity, pack/hold pressure at 60–80% of injection pressure for 2–5 seconds, and cooling time optimized based on wall thickness and cooling system design. Cooling optimization uses conformal cooling channels with turbulent water flow for maximum heat transfer.

   

  Quality Control and Assurance

  Incoming material control includes IV testing on each resin lot (target 0.78–0.85 dL/g), moisture verification upon receipt, and AA testing for sensitive applications. In-process control includes per-cavity weight monitoring (±0.2–0.5% tolerance), dimensional checks via optical inspection, and birefringence stress inspection under polarized light. Final inspection includes complete dimensional inspection via CMM, IV verification to confirm no hydrolysis, AA testing for odor-sensitive applications, and visual inspection for all cosmetic defects. Documentation includes material certificates, full dimensional reports with CPK data, IV and AA test results, and batch traceability records.

   

  Packaging and Fast Delivery

  Preforms are packed in inner plastic film liners inside outer paper cartons. Standard packaging quantities range from 500 to 1,300 pieces per carton depending on preform size. A full 20-foot container holds approximately 500 cartons, while a 40-foot HC holds approximately 1,200 cartons. Ansix Tech ensures delivery within the committed lead times through in-house manufacturing control and four-facility production capacity.

   

  Ansix Tech’s Industry Experience and Reliability

  With over 28 years of expertise, Ansix Tech has successfully delivered PET preform projects globally for cosmetics, personal care, and food packaging customers. The company’s integrated approach — from design through mold manufacturing to mass production — ensures value and reliability at every stage. Ansix Tech’s four production bases in China and Vietnam provide manufacturing flexibility, redundancy, and scalability unmatched by single-site competitors. Industry 4.0 intelligent manufacturing provides customers with data transparency and process control. And 28 years of injection molding expertise provides deep understanding of PET’s unique processing characteristics.

   

  Cost Reduction: The Ansix Tech Advantage

  Material cost reduction: Weight optimization eliminates over-specification — 1g savings across millions of units represents direct gross margin improvement. Hot runner systems eliminate runner waste — 100% material utilization compared to cold runner’s 70–85% material efficiency. Regrind management recovers production scrap value.

   

  Process efficiency improvement: High-cavity molds (96 cavities) maximize output per machine hour and per square meter of floor space. Conformal cooling reduces cycle time by 15–25%, increasing annual production capacity without additional capital investment. MES-driven process standardization reduces setup time between orders.

   

  Tooling cost reduction: DFM before mold construction eliminates rework cycles. In-house manufacturing eliminates supplier markup. Standardized mold designs leverage past learnings to reduce design time.

   

  Quality cost reduction: CpK ≥ 1.33 process capability minimizes scrap and rework. Per-cavity traceability enables rapid root cause identification. Low downstream defect rates reduce customer blow molding line rejects.

   

   

   

   

  Ansix Tech Co Ltd

  If you have any plans related to 85mm Neck, large diameter, 60g weight, wide mouth, PET food-grade plastic preform for shower gel bottles, blow molding preform tube , you can contact us at any time. We will turn your ideas into reality, let you realize your dreams, and obtain large orders from the market. Our contact information is info@ansixtech.com. Or contact our CTO, mail: stephen@ansixtech.com

   

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