IBM Machine Korea:
300ml HDPE Bottle Production Case Study

Volume

300 ml

HDPE IBM container for Korean household cleaner and pharmaceutical secondary packaging

Material

HDPE MI 0.3-0.8

High-density polyethylene IBM grade — ESCR F50 ≥200 h for household surfactant contact

Body OD

~62 mm

IBM body OD for 300ml format at body blow ratio 1.8-2.2x from preform. Zero parting line on body exterior

Wall

0.70-0.80 mm

HDPE IBM body wall — meeting Korean household bottle stacking and filling line drop impact specification

Neck

28/410 thread

Injection-moulded 28/410 GPI neck finish — ±0.05 mm OD across all ZQ110 cavities for Korean customer closure spec

Base

Injection-formed

Zero pinch-weld injection base — 2.0-2.5 mm base wall, flat ±0.15 mm for A-IL Plastic filling line conveyor stability

Q 01

Why is the ZQ110 the correct machine for 300ml HDPE rather than the ZQ80 or ZQ135?

The ZQ110’s 1,100 KN injection clamping force and 1,100 × 460 mm max platen are sized for the 8-12 cavity tooling footprint that 300ml HDPE bottle production requires at A-IL Plastic’s annual output target. The ZQ80 at 800 KN and 800 × 400 mm platen limits 300ml HDPE cavity count to 6-8 cavities — acceptable for lower volume programmes but not economically optimal at A-IL Plastic’s scale. The ZQ135 at 1,350 KN and 1,300 × 500 mm platen provides capacity for 12-14 cavities at 300ml but adds unnecessary machine cost, footprint and operating power versus ZQ110. Korea Ever-Power’s machine selection methodology calculates the minimum ZQ model whose platen area accommodates the target cavity count at the required container OD and height — producing the lowest capital cost recommendation for each customer’s production specification. For A-IL Plastic’s 300ml HDPE programme, ZQ110 was the correct result of this calculation.

Q 02

What HDPE grade does Korea Ever-Power recommend for 300ml household cleaner IBM containers?

Korea Ever-Power recommends HDPE IBM grade with melt index (MI) 0.3-0.8 g/10 min and ESCR F50 ≥200 hours for 300ml household cleaner bottles in contact with anionic surfactant formulations. The lower MI range (0.3-0.5) provides higher melt viscosity for better preform dimensional stability at the injection station, while MI 0.6-0.8 is acceptable for 300ml formats where the preform body is short enough to prevent sag. ESCR F50 ≥200 hours is the minimum for Korean household cleaner contact, where anionic surfactant concentration of 5-25% creates the most severe ESCR stress condition on the HDPE base-body junction zone. Korea Ever-Power specifies HDPE ESCR test (ISO 22088 Method 3 or ASTM D1693 Condition B, 10% Igepal CO-630) at pre-delivery production trial for all HDPE IBM containers destined for Korean household cleaner applications — ensuring the container meets the Korean customer’s shelf life and distribution stress requirements before delivery.

Q 03

How does Korea Ever-Power’s pre-delivery production trial work for a Korean customer like A-IL Plastic?

Korea Ever-Power’s standard pre-delivery production trial for Korean IBM machine customers is a formal qualification run conducted at Korea Ever-Power’s Ansan-si facility before machine and mould shipment to the Korean customer. The trial procedure: the production mould set (all cavities, production tooling) is mounted on the ZQ110 and run at production process parameters for a minimum 2-hour continuous run. Korea Ever-Power collects 10 containers per cavity from the stable production window and submits them to dimensional measurement (neck OD, body OD, height, weight per cavity) and visual inspection (flash, sink marks, colour consistency). The results are compiled into a Korea Ever-Power pre-delivery dimensional report issued with the machine — serving as A-IL Plastic’s Korean customer supplier qualification documentation. For HDPE household cleaner applications, Korea Ever-Power additionally conducts a container drop test (1.2 m onto concrete, filled to rated volume) and provides the drop test pass/fail result in the pre-delivery documentation package. This trial-before-ship protocol eliminates the machine and mould commissioning uncertainty that Korean customers otherwise face when sourcing IBM equipment from suppliers without in-house Korean production trial capability.

Q 04

What is the ZQ110 cycle time and annual output for 300ml HDPE IBM at A-IL Plastic’s cavity count?

At 10 cavities (a representative ZQ110 cavity count for 300ml HDPE on the 1,100 × 460 mm platen), the ZQ110 cycle time for 300ml HDPE IBM is 4.0-4.5 seconds. At 4.2 seconds cycle time and 10 cavities: 10 containers per cycle × (3,600/4.2) cycles per hour = approximately 8,571 containers per hour. At Korean 2-shift production (16 hours/day, 300 days/year): approximately 41M containers per year from one ZQ110. This output level is appropriate for A-IL Plastic’s Korean customer annual container procurement volumes in the 25-50M unit range typical for Korean mid-size household cleaner brands. If A-IL Plastic’s annual volume exceeds 50M containers at the 300ml format, a second ZQ110 or upgrading to ZQ135 (12-14 cavities) would be evaluated. Korea Ever-Power provides A-IL Plastic with the complete production capacity model (cycle time, cavity count, annual output at target shift pattern) as part of the machine sales process before order placement.

Q 05

Can the ZQ110 at A-IL Plastic run multiple container formats on the same machine?

Yes — the Korea Ever-Power ZQ110 at A-IL Plastic can run multiple 300ml and adjacent-format HDPE container designs through mould set changeover, provided the mould sets all fit within the ZQ110 platen envelope (1,100 × 460 mm) and bottle height (1-2,000 mm). Korea Ever-Power designs A-IL Plastic’s multi-format mould sets to share the same neck finish (28/410 in A-IL Plastic’s case) wherever possible, enabling core rod sets to be shared across multiple injection cavity designs and reducing total tooling investment. A-IL Plastic’s Korean production schedule on ZQ110 allocates weekly production blocks per container format, with Korea Ever-Power-trained mould changeover taking approximately 3-4 hours between format sets (injection cavity swap, blow mould swap, process parameter adjustment). The ZQ110’s European-style high-precision rotary table maintains alignment accuracy through repeated mould changeover cycles — A-IL Plastic does not need to re-qualify the machine after each mould changeover, only performing a 10-shot startup inspection per Korea Ever-Power’s changeover protocol.

Q 06

What after-sales support does Korea Ever-Power provide to Korean IBM machine customers?

Korea Ever-Power’s after-sales support programme for Korean IBM machine customers covers four structured service areas. Installation and commissioning: Korea Ever-Power senior engineers travel to the Korean customer facility for machine installation, mould mounting, process parameter setup and operator training covering machine operation, mould processing and maintenance procedures. Korea Ever-Power trains A-IL Plastic operators on ZQ110 startup, mould changeover, process adjustment and routine daily maintenance to ensure the Korean customer achieves stable production without ongoing Korea Ever-Power engineer involvement after initial commissioning. Preventive maintenance: Korea Ever-Power provides A-IL Plastic with a ZQ110 preventive maintenance schedule covering hydraulic oil change intervals, rotary table lubrication points, injection barrel wear monitoring and mould re-polish service intervals. Korea Ever-Power sends reminder notifications to A-IL Plastic at each scheduled maintenance interval. 24/7 maintenance service hotline: Korea Ever-Power maintains a service hotline available 24 hours/day for Korean customer emergency production support — remote diagnosis and Korea-based technical telephone support for ZQ110 production troubleshooting at A-IL Plastic’s Korean facility. Spare parts supply: Korea Ever-Power maintains adequate spare parts inventory in Ansan-si for ZQ series components including hydraulic seals, barrel wear parts, rotary table bearings and electrical components — with parts shipping to Korean customers within 24-48 hours for in-stock items.