A Comprehensive Guide to Eight Categories of Injection Bottle Molds

As a professional bottle container manufacturer, understanding the different types of injection molds at our disposal is vital. These molds, each with their unique characteristics, play a significant role in shaping the quality, design, and production efficiency of our products. In this comprehensive guide, we will explore eight categories of injection bottle molds that are pivotal in the bottle manufacturing industry.

1. Single-Stage Injection Molds

Single-stage injection molds are an embodiment of manufacturing efficiency. As the name suggests, these molds combine the injection and blow molding stages into one continuous process within a single machine.

This type of mold is particularly useful for specialty bottle manufacturing and limited production runs. Single-stage injection molds guarantee an elevated level of precision in design and dimensional consistency, ensuring the highest quality standards for our customers.

2. Two-Stage Injection Molds

Two-stage injection molds take a two-step approach to bottle manufacturing. The first stage involves an injection molding machine that creates a plastic preform. This preform then moves onto the second stage – the blow molding machine – where it is inflated into the shape of the final product.

This mold category is well-suited for high-volume production due to its enhanced capacity and efficiency. Despite the two-step process, two-stage injection molds still maintain high accuracy levels, ensuring our products’ quality and consistency.

3. Hot Runner Molds

In hot runner molds, the plastic is guided from the injection unit to the mold cavity via a heated physical channel, or “runner.” These molds are designed to maintain the plastic in a molten state, preventing it from solidifying and blocking the runner.

Hot runner molds offer significant advantages in terms of cost efficiency and sustainability by minimizing plastic waste. This mold type is particularly beneficial when working with PET (Polyethylene Terephthalate), reducing the risk of material degradation and ensuring our PET bottles’ superior quality.

4. Cold Runner Molds

Cold runner molds, in contrast to their hot counterparts, guide the plastic into the mold cavity through unheated channels. Once the injection process is complete, the plastic within the runner solidifies.

While cold runner molds may produce more waste due to the unused plastic in the runner system, they offer substantial flexibility. Quick color changes and the ability to use different materials make these molds an excellent choice for specialty or low-volume bottle production.

5. Multi-Cavity Molds

Multi-cavity molds are a game-changer for high-volume bottle manufacturing. These molds contain multiple cavities identical in shape, allowing the simultaneous production of numerous bottles.

Multi-cavity molds dramatically increase production efficiency without compromising the quality and uniformity of our products, ensuring that we can meet high demand quickly and effectively.

6. Family Molds

Family molds bring versatility to the production line. These molds feature multiple cavities of different shapes and sizes within one mold, enabling the simultaneous production of various bottle components, such as the body and cap.

Family molds streamline the assembly process, offering a convenient and cost-effective solution for manufacturing complete bottle units in one go. This mold category ensures that all the bottle components are consistent in quality and compatibility.

7. Three-Plate Molds

Three-plate molds are characterized by their unique design comprising two parting lines and three plates clamped together. This design allows for a higher number of cavities per mold, increasing production output.

These molds enable precise center gating, which is advantageous for manufacturing symmetrical or round bottles. The three-plate molds ensure that our bottles are uniformly shaped, aesthetically pleasing, and reliable in quality.

8. Stack Molds

Stack molds offer an innovative solution to multiply production output without increasing machine size or footprint.

Can perfume be brought on board an airplane?

Perfume is classified as a liquid cosmetic product. According to the regulations outlined in the “Civil Aviation Administration: FAQ on Passenger Carry-on Baggage Security Measures,” passengers are not allowed to carry perfume bottles with an individual volume exceeding 100 milliliters (mL). The perfume must be placed in a transparent plastic bag with a maximum size of 20x20cm, which can be resealed (only one sealed bag containing liquid containers is allowed). The total volume of liquid within the sealed bag in the carry-on baggage must not exceed 1 liter (L).

Example scenarios:

(Allowed) Jo Malone 30ml x1, Toner 50ml x1, Styling Spray 50ml x1 (all volumes are less than or equal to 100 milliliters)

(Not allowed) CK 200ml x1, Dolce & Gabbana 50ml x1, Hermes 30ml x1 (CK exceeds 200 milliliters)

*Note: The determination of milliliter measurements is based on the volume indicated on the bottle, not the amount remaining. Therefore, if you have a perfume bottle with a capacity of 100 milliliters, but only 30 milliliters are left, it is still considered 100 milliliters. If you want to make the most of the milliliter restriction, it is recommended to transfer the perfume into smaller bottles.

The degradation principle of biodegradable plastics

Biodegradable plastics generally meet the requirements for physical properties of traditional plastics and can be widely used in daily necessities, commercial, and industrial fields. The main reason is that biodegradable plastics are more environmentally friendly materials than traditional plastics, which can alleviate problems such as plastic pollution and resource waste, and reduce the negative impact of humans on the earth and the ecological environment.

Biodegradable plastics are plastics that can be decomposed in specific environments and are usually made from biomass materials, starch, polylactic acid, etc. Biodegradable plastics can be broken down into smaller molecules and ultimately decomposed by microorganisms into natural compounds such as carbon dioxide and water, which will not cause permanent damage to the environment.

The principle of biodegradable plastics can be divided into three mechanisms: physical degradation, chemical degradation, and biological degradation:

Physical degradation: When biodegradable plastics are subjected to external forces such as mechanical, light, and temperature, the molecular chains are prone to break, and the plastic will be broken into small particles, ultimately forming environmental pollutants such as microplastics in the ocean.

Chemical degradation: Under the influence of chemical reactions such as oxidation, heating, and radiation, the bond structure in biodegradable plastics will break, causing the molecular chain to break and convert into small molecules such as water, carbon dioxide, and methane. Chemical degradation is usually faster than physical degradation.

Biological degradation: Some biologically active ingredients such as starch, polyhydroxy fatty acid esters are added to biodegradable plastics, making them able to be absorbed and decomposed by microorganisms, forming harmless substances such as water and carbon dioxide, thus achieving environmental friendliness.

It should be noted that although biodegradable plastics can decompose in their natural environment, this is only for natural conditions that meet regulations, such as temperature, humidity, acidity and alkalinity, etc. If the conditions are not met, biodegradable plastics can still cause environmental pollution. Therefore, it is crucial to use and handle biodegradable plastics reasonably.

EcoMark Natural Branding is a new, sustainable, and cost-effective alternative to production unit labels that has the potential to completely eliminate those annoying fruit stickers and accompanying silicon. It is also free of any ink. The new system does not require a label applicator, let alone the high, absurd return on investment associated with it. Due to its zero-label cost and non-consumptive nature, its benefits are infinite.

The new laser technology can be applied to any robust-skinned food, including apples, avocados, apricots, bananas, grapefruit, kiwis, lemons, limes, oranges, pears, tangerines, papayas, peaches, persimmons, coconuts, figs, pomegranates, plums, lychees, mangoes, corn, chili peppers, cucumbers, ginger, garlic, onions, carrots, celery, tomatoes, pumpkins, zucchinis, artichokes, beets, Brussels sprouts, cabbage, eggplants, fennel, peas, potatoes, sweet potatoes, asparagus, radishes, turnips, and cauliflower.

The system uses lasers for marking to ensure brand compliance with SKU-level identification, validation of traceability and authenticity, while ensuring no long-term damage to fruits and vegetables and virtually undetectable calorie impact. The system’s advantage is that it only removes the top layer of cells from the fruit’s skin, removing the outermost layer of skin to ensure fruit integrity.

The increasing demand for Post-Consumer Recycled plastic(PCR)

Post-Consumer Recycled plastic (PCR) refers to raw materials derived from plastic waste generated by households, businesses, industries, and organizations through recycling channels after being used by end-users.

This includes plastic returned from logistics and distribution chains, such as used food and personal care packaging, household appliances, and dismantled automobiles. The demand for Post-Consumer Recycled plastic signifies higher environmental significance and market value. The promotion of “proportionate use of recycled plastic” by consumer goods brands emphasizes the utilization of Post-Consumer Recycled plastic.

Post-Consumer Recycled plastic (PCR) is the truly recyclable plastic that the plastic value chain needs to circulate in order to achieve sustainable development goals.

Here are the relevant national policies regarding PCR plastic:

01 United States:

The American Chemistry Society (ACS) proposed to the U.S. Congress that packaging should be mandated to use a minimum of 30% recycled materials.

In July 2021, the American Chemistry Society released five action plans, suggesting that the U.S. Congress should take measures to improve plastic recycling rates.

02 European Union:

In 2019, the European Parliament and the Council of the European Union issued the “Directive on Reducing the Impact of Certain Plastic Products on the Environment” (EU2019/904), which sets a target for each member state to have a minimum of 25% recycled plastic content in some PET containers by 2025.

By 2030, a minimum of 30% recycled plastic should be incorporated into some beverage bottles.

03 Australia:

By 2025, plastic packaging should contain 20% recycled content.

The “National Plastic Plan 2021” in Australia sets a target for plastic packaging to have 50% recycled content by 2025, with plastic packaging specifically containing 20% recycled content.

The “National Waste Policy Action Plan 2019” mentions the goal of banning the export of plastic waste, paper, glass, and tires from the second half of 2020 to provide sufficient recycled materials as raw materials domestically.

04 Japan:

In 2019, the Ministry of the Environment in Japan, through a panel of experts under the Central Environment Council, formulated the final version of its plastic recycling strategy, which aims to reduce single-use plastic containers and packaging by 25% by 2030 and implement mandatory charges for shopping bags.

Additionally, the strategy aims to increase the reuse and recycling rates of plastic containers and packaging to approximately 60% by 2030 and achieve 100% effective utilization of all used plastics, including thermal recycling, by 2035.

05 United Kingdom:

Plastic packaging tax is imposed, with a tax applicable if the recycled content is below 30%.

On November 12, 2020, HM Revenue and Customs in the UK issued a draft legislation for the plastic packaging tax, which applies to plastic packaging produced or imported into the UK and requires a minimum of 30% recycled plastic content.

It was legislated in the Finance Act 2021 and came into effect on April 1, 2022.

06 India:

The first Asian country to launch the “Plastic Convention”: By 2030, the average recycling content of all plastic packaging should be 25%.

The “Plastic Convention in India” focuses on four targets by 2030: creating a list of single-use plastics, making 100% of plastic packaging reusable or recyclable, achieving effective recycling of 50% of plastic packaging, and ensuring an average recycling content of 25% in all plastic packaging.

07 South Korea:

By 2025, South Korea aims to increase the recycling rate of plastic waste from the current 54% to 70%.

In December 2020, South Korea planned to reduce plastic waste by reducing plastic production and increasing recycling rates.

South Korea plans to reduce plastic waste by 20% and increase the recycling rate of plastic waste from the current 54% to 70% by 2025.

08 Canada:

By 2025, Canada aims to achieve the use of 30% recycled materials in all plastic packaging. The organization “Canada Plastic Pact” hopes that by 2025, all its partners will achieve the following objectives:

Identify problematic or unnecessary plastic packaging and take measures to address them.

Achieve 100% reusable, recyclable, or compostable plastic packaging.

Ensure that 50% of plastic packaging is recycled or composted.

Achieve the use of 30% recycled materials in all plastic packaging.

The production process of PET bottles can be divided into four stages: stretching, pre-blowing, blowing, and cooling.

Stretching: In this stage, preheated PET preforms are fed into a stretching machine, clamped by the machine’s fixtures, and stretched into a longer tube-like shape. During this process, PET molecular chains are stretched, making them more closely packed together, which helps to enhance the strength and durability of PET material. In addition, stretching can also control the size and thickness of PET bottles to ensure that the bottles meet relevant standards and specifications. The stretched PET preforms are more suitable for blowing into bottle shapes and help to reduce material waste in the bottle production process.

Pre-blowing: PET tube-shaped bodies are gradually expanded into bottle shapes through the heating and pressure of the nozzle in this process. During this process, PET material is heated and slowly inflated to gradually adapt to the required bottle shape. This reduces the stress and deformation of PET material in the subsequent blowing process, thereby improving the quality and consistency of the bottle. In addition, pre-blowing can help to evenly distribute PET material throughout the bottle, reducing defects and bubbles in the bottle.

Blowing: In this stage, PET material needs to be heated and shaped under precise temperature and pressure control to ensure that the size and shape of the bottle meet requirements. Through blowing, PET material can be molded into various shapes and sizes of bottles, such as plastic water bottles, beverage bottles, and so on. The blowing process can also incorporate customized designs and printing onto PET bottles to meet different product and market demands. For example, trademarks, labels, and other information can be printed on PET bottles to increase brand awareness and market share.

Cooling: After blowing is completed, the bottle needs to be cooled to fix its shape and size. This is usually done by spraying water or placing the bottle in a cooling chamber. Because PET bottles are very hot after blowing, if they are not cooled, they may lose their original shape and size, and even deform or develop bubbles. Cooling helps to rearrange and solidify the molecules in PET material, ensuring that the bottle maintains its required shape and size. In addition, cooling can also help to harden the PET bottle quickly, reducing defects and bubbles on the bottle surface, making it more aesthetically pleasing. At the same time, cooling can improve the production efficiency of PET bottles, enabling them to be processed and packaged more quickly.

How to foil seal laminated soft tube?

1,Before starting to apply the foil seal on the soft tube mouth, the first important thing we need to do is to clean the mouth. The tube mouth must be dry and clean, so that the foil seal will be strongly stuck to the mouth. If the tube mouth is dirty and full of dust, it will affect the sealing effect.

2, Peel off the tube foil seal from the paper sheet, apply it to the surface of the tube mouth and smooth it by your finger. At this moment, the foil seal looks smoothly from the appearance.

3, Screw on the plastic lid to the tube mouth. It will tighten the foil seal strongly. If you reopen the plastic lid, you will find the foil seal perfectly sticking to the mouth surface, which means everything are done.

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Why use aluminum foil seal?

Aluminum foil seal can block the product inside the container from direct contact with the outside air. It can keep the quality of the product unchanged for a long time, and alleviate the bottleneck chipping caused by handling or transportation.

The advantages of foil seal gaskets: dustproof, waterproof,anti-breakage,moistureproof

Seal foil is widely used in PET, PE, PP, PVC, PS, ABS, metal, aluminum and glass bottles containers.

Machines required for pressure-sensitive foil sealing gasket:

Generally, no sealing equipment is required.
1) Insert the pressure-sensitive gasket into the bottle cap with the letter side facing up, the white side facing down
2) Tighten the bottle cap.

Machines needed for aluminum foil gasket sealing:
1. Hand-held sealing equipment
1) Insert the aluminum foil gasket into the bottle cap so that the aluminum foil is facing outwards
2) Tighten the bottle cap and place it on the sealing machine
2, Auto machine: Adjust the power and time of the sealing machine, press the red switch buttom.
The sealing equipment of the automatic production line can be operated according to the specific sealing equipment manual.

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Airless pump bottle vs HDPE bottle

Airless pump bottles and HDPE bottles are both popular packaging options, each with their own unique benefits and drawbacks. The choice between the two ultimately depends on the specific needs and characteristics of the product being packaged. Here are some factors to consider when deciding between airless pump bottles and HDPE bottles:

Airless pump bottles:

Benefits: Airless pump bottles are designed to dispense the contents without allowing air to enter the container, which can help to preserve the product’s quality and prevent oxidation. They are often used for skincare products, such as creams, serums, and lotions. Airless pump bottles also provide precise dispensing, which can help to reduce waste and ensure that the right amount of product is used each time.

Drawbacks: Airless pump bottles can be more expensive than other packaging options.

HDPE bottles:

Benefits: HDPE bottles are lightweight, durable, and resistant to impact and moisture, making them a good option for a wide range of products. They are often used for products such as shampoos, conditioners, and other liquids. HDPE bottles are also less expensive than many other packaging options and can be easily recycled.

Drawbacks: HDPE bottles are not always completely airtight, which can allow air to enter the container.

In general, if your product requires airtight packaging and precise dispensing, an airless pump bottle may be the better choice. If durability and affordability are the top priorities, an HDPE bottle may be a good option.