Blowmoulding not only requires hardware like an extruder, a clamp section, and support equipment, but also relies on the most important ingredient – trained personnel. Blowmoulding is something less than an absolute science. Though the machines and equipment run automatically, qualified technical and semi-skilled workers are necessary to setup and refine the machinery’s operation, monitor and correct process conditions, and make repairs. They also perform quality inspections, visually inspect and pack blowmoulded parts, and handle and care for expensive resins.
Trained Personnel
Managers are needed to coordinate the activities of all the groups and individuals involved in this process. One group is the setup mechanics and process technicians who ready blowmoulding equipment for production. Moulds, blow pins, and tooling must be precisely installed in the machine. Temperatures and machine timing must be set and adjusted until optimum quality and production rates are achieved. Once the machine is up and running, we are not on automatic pilot, so to speak.
Extrusion rates will fluctuate with the density of the resin, parisons will drift slightly out of position, mould pinch areas wear, deflashing equipment creeps out of adjustment, colours go light and dark, and tooling requires cleaning.
Usually, three groups of workers are on staff to deal with the numerous processing drifts. The machine mechanics anticipate problems and make adjustments like parison centring, changing worn deflashing sleeves, and extruder speed adjustments.
The packer inspectors sort out any visually defective parts like dirt or foreign material in the resin or parts that haven’t been completely deflashed, and an occasional hole. They pack the good ones in shipping containers and grind the bad ones in the granulator.
The quality insurance inspectors measure and test samples to assure that the parts produced are being made to certain specifications. Details like legal volumes and dimensions of an area that must work with another part, like a cap, are verified.
Quality Insurance Inspectors
There are other groups of personnel that have responsibilities in the manufacturing process. The material handlers assure a continuous supply of properly dried and blended to the machines. They adjust blender settings and monitor and handle excess regrind accumulations. They move in supplies of shipping containers and move out loads of finished goods.
Maintenance personnel perform the preventative maintenance routines on the equipment and the moulds and tooling. They also do heavy duty repair jobs like motor replacements and equivalent overhauls.
Maintenance Personnel
The vital link between the production team and management is the production supervisor. The supervisor must coordinate everyone’s activities and make decisions to assure that manufacturing proceeds profitably and safely. The supervisor monitors proper usage of raw material while maintaining quality standards and production output. He or she prepares various reports and communicates to upper management the needs of the blowmoulding department.
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