Μηχανή χύτευσης με έγχυση EP-ZQ110

Επισκόπηση προϊόντος

The EP-ZQ110 is the largest standard-configuration model in Korea Ever-Power's μηχανή χύτευσης με έγχυση line before the flagship ZQ135. It is the machine that Korean large-scale pharmaceutical contract manufacturers specify when 24-cavity 10 ml or 14-cavity 100 ml output per machine is the production requirement, and when the economics of two ZQ80 machines (at a higher combined investment and greater factory footprint than one ZQ110) no longer justify themselves versus the consolidation of output onto a single heavy-duty platform. At 1,100 KN injection clamping, the ZQ110 carries 37.5% more clamping force than the ZQ80 — a margin that matters at 24 cavities when the cumulative projected cavity area resisting injection pressure is at its maximum across the series.

The ZQ110 inherits both premium engineering features that distinguish the ZQ80 from lower-series models: the high-precision angle divider that synchronises mould opening and closing with turret lift for repeatable 24-cavity indexing, and the standard dual hydraulic system (22+22 KW) that delivers 20–30% lower energy consumption than single-circuit competitors at the same machine class. These features are included as standard on the ZQ110, not as upgrades — Korean customers do not pay a premium at time of order to access the productivity and energy efficiency advantages they deliver. The 4+N barrel zone configuration (first introduced in the ZQ series at the ZQ80) continues on the ZQ110, providing the finer gate-zone temperature control that managing large shot weights through 24-cavity hot runner networks requires.

The ZQ110's 65 mm screw and approximately 650 g shot weight serve the largest mould configurations in the ZQ hydraulic series: a full 24-cavity 10 ml hot runner injection mould requires a total runner and cavity resin volume that exceeds the ZQ80's 55 mm / 466 g capacity. The ZQ110's larger shot weight ensures that all 24 cavities fill simultaneously from a single injection shot without the short-shot risk at the periphery of the hot runner network that occurs when shot weight is marginal relative to the cavity count. At container volumes of 250 ml and above, the ZQ110's 10-cavity 250 ml and 6–8 cavity 500 ml configurations make it a commercially important machine for Korean bulk personal care packaging, Korean cooking oil bottling and Korean industrial chemical container production at output rates that no ZQ60 or ZQ80 can match from a single machine.

Technical Specifications — EP-ZQ110

The following parameters are Korea Ever-Power's engineering specifications for the EP-ZQ110. Core confirmed specifications are indicated; additional parameters follow the ZQ series engineering progression and should be verified with Korea Ever-Power's technical team during site preparation planning. All parameters are for reference and may be updated without notice.

Parameters marked "approx." are based on ZQ series engineering progression and should be verified with Korea Ever-Power's technical team. All parameters for reference only.

EP-ZQ110 Cavity Count Reference by Bottle Volume

(Estimated based on ZQ series engineering progression — confirm with Korea Ever-Power for specific mould configurations)

Cavity counts are for reference. Korea Ever-Power reserves the right to modify specifications without notice.

EP-ZQ110 Production Line: 3-Station Process at 24-Cavity Scale

The EP-ZQ110 operates on the same 3-station concurrent-processing principle as all ZQ series machines, with all three stations — injection, blow moulding, and stripping — executing simultaneously on 24 independent mandrel sets. At the ZQ110's scale, the production line around the machine requires proportionally more careful planning than lower-series models: at 24-cavity 10 ml output at approximately 21,600 bottles per operating hour, the downstream conveyor, inspection, labelling and counting equipment must be able to keep pace without the accumulation buffer becoming a production bottleneck.

Station 1 — Preform Injection at 1,100 KN

At 1,100 KN injection clamping, the ZQ110 holds a 24-cavity preform mould closed against injection pressure that would cause mould flash or cavity-face separation on machines rated below this threshold at this cavity count. The 65 mm screw delivers approximately 650 g per shot — sufficient to fill all 24 cavities simultaneously through the hot runner network without the pressure drop across the outer cavities causing short-shots or weight variation between inner and outer cavities. The 4+N barrel zone configuration provides the gate-zone temperature fine-tuning needed to manage resin viscosity at the end of the 24-drop runner network, where flow path length is greatest and melt temperature drop is most significant. The high-precision angle divider begins coordinating the mould-close and turret-lift motions at the end of each cycle, ensuring that the 24 mandrels register to the 24 preform cavities with the same angular precision on cycle 1 as on cycle 1,000,000.

Station 2 — Simultaneous 24-Cavity Blow Moulding

All 24 preforms are inflated simultaneously at the blow station, supported by approximately 150 KN blow clamping and the dual hydraulic system's Circuit B — independent of the injection-side Circuit A. The dual circuit independence is especially important at 24-cavity blow production: in a single-circuit machine, the blow phase immediately follows the injection phase and shares the hydraulic pump that was under maximum load during injection. The residual pressure fluctuation from that transition reaches the blow station and creates non-uniform blow pressure across the 24 cavities. The ZQ110's dual circuit eliminates this entirely: Circuit A handles injection and recovers while Circuit B handles blow clamping independently at its own steady-state pressure, producing uniform wall thickness distribution across all 24 cavities that single-circuit machines at this cavity count cannot reliably achieve.

Station 3 — Output at 24-Bottle-per-Cycle Rate

Twenty-four finished bottles are stripped and deposited to the output conveyor every cycle — at the ZQ110's 4-second cycle time, this is a conveyor input rate of 6 bottles per second, or approximately 21,600 bottles per operating hour at 90% efficiency. Korea Ever-Power's production line planning team advises on conveyor speed, accumulation capacity, and the number and type of downstream inspection stations (weight check, dimensional gauge, vision system) required to process the ZQ110's output without creating a downstream bottleneck that forces the machine to be stopped waiting for downstream clearance. For Korean pharmaceutical production lines, a buffer accumulation table between the ZQ110 and the filling or labelling line is typically specified with sufficient capacity for 5–8 minutes of ZQ110 output — approximately 1,800–2,880 bottles at 10 ml format.

EP-ZQ110 at 1,100 KN: Engineering Profile and Series Position

The EP-ZQ110 sits at a specific and commercially well-defined position in the ZQ hydraulic series. It is the first model to cross the 1,000 KN injection clamping threshold and the first to achieve 24-cavity production at 10 ml — the standard maximum cavity count for Korean large-scale pharmaceutical IBM production on a hydraulic platform before moving to the ZQ135. Understanding where the ZQ110 sits in the series, and what the 1,100 KN clamping force specifically enables, helps Korean factory engineers justify the ZQ110 against both ZQ80 and ZQ135 alternatives.

IBM vs ISBM: Technology Choice at ZQ110 Investment Scale

Η Korea Ever-Power κατασκευάζει τόσο τις μηχανές IBM σειράς ZQ όσο και τις μηχανές ISBM σειράς HGY, οι οποίες διατίθενται στην Σειρά μηχανημάτων ISBM 4 σταθμών. At the ZQ110 investment scale, the IBM vs ISBM process question typically resolves quickly on material grounds: the ZQ110 is the correct machine for Korean operations producing HDPE and PP containers, where no ISBM machine can match the ZQ110's 24-cavity output rate or its material handling range. ISBM machines in the HGY series are the correct choice for Korean operations requiring crystal-clear biaxially oriented PET cosmetic or beverage containers — a fundamentally different material and bottle physics requirement from the HDPE pharmaceutical bottles that define the ZQ110's primary market.

For Korean factory investors whose production is anchored in HDPE and PP pharmaceutical, household chemical or food packaging — the ZQ110 is the technology of choice and no ISBM machine is a substitute at this output scale. For investments that bridge both HDPE pharmaceutical and PET cosmetic production in the same facility, Korea Ever-Power at isbm-blow-molding.com can advise on the correct machine combination.

EP-ZQ110 Application Fields

Essential Matching Components for the EP-ZQ110

• ZQ110 IBM Mould Set — 24-Cavity Precision Engineering
  The ZQ110's 24-cavity mould set is the most complex tooling Korea Ever-Power builds for the standard ZQ hydraulic series. The 24-drop hot runner system requires gate balance engineering verified by simulation to within ±1.5% flow variation across all 24 gates before CNC machining begins — a tighter specification than the ZQ80's 20-cavity ±2% target. S136 stainless steel (HRC 50–52) is used for all injection cavity bodies and core rods. The 24-cavity trial run at Korea Ever-Power's facility produces a cavity-by-cavity weight and neck OD report across 500 consecutive shots, confirming that the maximum cavity-to-cavity weight deviation is within the Korean GMP qualification limit before the mould leaves the factory. Mould set weight at 24 cavities requires a floor-mounted crane or mould handling trolley rated for 150–200 kg at the customer's facility.
• Oil-Free Air Compressor (0.7–1.2 MPa, 1.2 M³/min recommended)
  At 24-cavity blow production, the simultaneous air inflation of 24 preforms per 4-second cycle creates a compressed air demand profile that benefits from a compressor sized above the ZQ110's minimum 0.7 M³/min specification. Korea Ever-Power recommends 1.2 M³/min compressor capacity with a 400-litre minimum air receiver for ZQ110 installations, providing the buffered supply that prevents line pressure drops during the simultaneous 24-cavity blow event. Oil-free screw compressor specification remains mandatory for Korean pharmaceutical and food-grade IBM production on the ZQ110.
• Dual Mould Temperature Controllers and Chiller (5 M³/h cooling circuit)
  The ZQ110 requires approximately 5 M³/h cooling water at 0.3–0.4 MPa — reflecting the larger mould cooling area of the 24-cavity configuration and the higher heat input from 80 KW total power (versus the ZQ80's 55 KW). Korea Ever-Power recommends two independent mould temperature controller units (one injection mould circuit, one blow mould circuit) as on the ZQ80, with each unit sized for the full 5 M³/h flow split appropriately between the two circuits. The chiller capacity for the ZQ110 should be sized against the full 80 KW installed power as the worst-case thermal load rather than the lower operating power draw, ensuring adequate cooling reserve during ZQ110 startup phases when thermal load peaks.

Why Choose Korea Ever-Power for the EP-ZQ110?

• 1,100 KN at 20–30% above industry standard, with 20–30% energy saving: The ZQ110 delivers class-leading clamping force and class-leading energy efficiency simultaneously — a combination that defines Korea Ever-Power's European-architecture approach, where structural integrity and operating economy are not traded against each other.
• 24-cavity mould set engineered and trialled in-house: At 24 cavities, the mould set is the most demanding tooling in the standard ZQ series. Korea Ever-Power designs, machines, assembles and trial-runs the ZQ110 24-cavity mould on its own ZQ110 test machine, delivering a documented cavity-by-cavity qualification report with every mould set. Korean pharmaceutical customers receive GMP-qualifying documentation from the machine manufacturer — not from a separate mould vendor whose machine the Korean customer cannot visit.
• Standard high-precision angle divider and dual hydraulic system: Both premium features that differentiate the ZQ110 from lower-class machines are included as standard — not as options with additional lead time and cost. Korean ZQ110 customers receive the full cycle repeatability, indexing precision and energy efficiency of these systems from the first production day.
• Πιστοποίηση CE και ISO 9001:2015 με πλήρη τεκμηρίωση: The full ZQ110 documentation package — CE Declaration, operation and maintenance manual, hydraulic and electrical schematics, spare parts catalogue, mould qualification report — is included with every ZQ110 delivery. Korean pharmaceutical GMP supplier qualification files can be built directly from Korea Ever-Power's standard delivery package without requesting supplementary documentation.
• Clear path within the ZQ platform family: Korean factories commissioning a ZQ110 are investing in a platform architecture that scales to the ZQ135 if production demands ever require 30-cavity output. Operator training, spare parts ecosystem and process knowledge accumulated on the ZQ110 carry directly to the ZQ135 without a learning curve restart.
• 24×7 service with Korea-dedicated spare parts inventory: At ZQ110 production rates, each hour of unplanned stoppage is commercially significant. Korea Ever-Power maintains a dedicated Korean-market spare parts inventory for express dispatch to Korean production facilities, supplemented by 24-hour remote PLC diagnostic access for immediate process and control issue resolution.

Frequently Asked Questions — EP-ZQ110

Q1: What is the practical output difference between the ZQ80 at 20 cavities and the ZQ110 at 24 cavities for 30 ml pharmaceutical vials?

At 30 ml HDPE pharmaceutical vials and 4-second dry cycle, the ZQ80 at 20 cavities produces approximately 18,000 vials per operating hour at 90% efficiency. The ZQ110 at 20–22 cavities (30 ml format) produces approximately 19,800–22,000 vials per operating hour at the same efficiency — approximately 10–22% more output per hour depending on mould configuration. For Korean pharmaceutical contract packagers who run 30 ml vials as their highest-volume format across multiple shifts, the ZQ110's additional cavity count at this format translates to approximately 360,000–720,000 additional vials per production day over the ZQ80. Over a 250-day Korean production year, that represents a significant additional capacity that avoids the need for a second machine investment to meet volume commitments.

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Q2: Why does the ZQ110 use 1,100 KN rather than a lower figure — could a 900 KN machine run 24 cavities?

At 24 cavities producing 10 ml pharmaceutical containers, the cumulative projected area of all 24 neck cavities in the injection mould resisting injection pressure requires approximately 45 KN of clamping force per cavity to prevent flash formation at the neck parting line. At 1,100 KN, the ZQ110 provides 1,100 ÷ 24 = approximately 46 KN per cavity — within the safe margin. A 900 KN machine at 24 cavities would provide 37.5 KN per cavity — below the safe threshold for HDPE at standard injection pressure, which typically produces flash at the neck parting line that fails Korean GMP dimensional requirements. The 1,100 KN specification is not a safety margin above the minimum; it is the minimum correct specification for flash-free 24-cavity neck production at standard HDPE injection conditions.

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Q3: How does the ZQ110 manage shot weight variation across 24 cavities through the hot runner network?

Gate balance in a 24-cavity hot runner system is the primary engineering challenge in ZQ110 mould design. Korea Ever-Power's ZQ110 mould engineering process uses mould flow simulation (Moldflow or equivalent) to verify that all 24 gate positions fill within ±1.5% flow variation before CNC machining begins. If simulation shows imbalance in the initial runner geometry, the hot runner base gate diameter or runner diameter is adjusted iteratively until balance is confirmed by simulation. After machining, the first production trial confirms balance by measuring cavity weight from all 24 cavities across 50 consecutive shots — any cavity whose weight deviates more than ±2% from the mean triggers a gate adjustment before the mould is cleared for delivery. The 4+N barrel zone configuration on the ZQ110 also contributes to gate balance by allowing the barrel's gate-end zone to be held at a temperature setpoint optimised for uniform melt viscosity at the hot runner gate entry — reducing the viscosity variation that causes flow imbalance in large multi-cavity networks.

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Q4: What is the actual daily output of the EP-ZQ110 at 24-cavity 10 ml production?

At a 4-second dry cycle, practical production efficiency of 88% (accounting for shift startup, minor format adjustments and scheduled cleaning), the ZQ110 completes approximately 792 cycles per operating hour. At 24 cavities: approximately 19,008 units per operating hour. On a Korean two-shift day of 14 production hours: approximately 266,000 units per day. On a 250-day production year: approximately 66.5 million 10 ml pharmaceutical containers per year from one ZQ110. This annual output is sufficient for a Korean pharmaceutical contract packager supplying 10 ml ophthalmic containers to multiple Korean hospital pharmacy systems simultaneously, without requiring a second IBM machine. The ZQ110's annual capacity at this format exceeds the combined annual output of two ZQ60 machines at 14-cavity 10 ml production — one ZQ110 can replace two ZQ60 platforms with a smaller combined footprint and one set of operating costs.

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Q5: What electrical supply does the EP-ZQ110 require?

The EP-ZQ110 requires 80 KW total installed power at 380V / 3-phase / 50 Hz. The dual motor configuration is 22 KW + 22 KW for the two hydraulic circuits, plus 22 KW barrel heating and auxiliary loads. Korea Ever-Power recommends sizing the ZQ110's dedicated circuit at 95 KW to provide adequate startup headroom. A 150A / 380V three-phase circuit with soft-start or star-delta starters on both 22 KW hydraulic motors (to limit startup current inrush) and earthing to Korean KS C IEC 60364 industrial standards is the recommended ZQ110 electrical supply specification. Korean factory power distribution panels serving the ZQ110 area should be verified against this load before installation begins — the ZQ110's 80 KW total installed power is significantly higher than the ZQ80's 55 KW and requires the Korean factory's power distribution engineer to confirm that the existing incoming supply capacity supports this additional load.

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Q6: Why does the ZQ110 weigh 15 tonnes when the ZQ80 is 10 tonnes?

The 50% weight increase from ZQ80 to ZQ110 reflects the larger machine chassis, heavier clamping mechanism required to deliver 1,100 KN (versus 800 KN), larger hydraulic components for the higher-output 22+22 KW dual circuit, larger barrel and injection unit for the 65 mm screw, and the extended platen assembly needed for the 24-cavity mould set. The structural frame of the ZQ110 must absorb significantly higher mechanical loads during injection clamping than the ZQ80, requiring heavier-gauge steel construction throughout. The 15-tonne weight has a practical implication for Korean factory installation: the ZQ110 requires structural floor load capacity of at least 1,500 kg/m² under the machine footprint of 5 × 1.8 m (9 m²), which should be verified with the Korean factory's structural engineer before delivery. Most Korean purpose-built industrial packaging factory floors meet this specification; general light-industrial floors may require reinforcement assessment.

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Q7: What floor space does the complete EP-ZQ110 production cell require?

The EP-ZQ110 machine footprint is 5 × 1.8 m (9 m²) at 2.2 m height. A complete ZQ110 production cell — machine, output conveyor (3–5 m extension), oil-free compressor, dual chiller units, dual mould temperature controllers, electrical panel, mould handling trolley and operator station — requires approximately 50–65 m² of floor space depending on the conveyor length and auxiliary equipment arrangement. For Korean pharmaceutical GMP production areas, additional buffer accumulation space beyond the conveyor is typically allocated — approximately 10–15 m² of additional clear floor area adjacent to the ZQ110 cell for quality control sampling and first-article inspection without interrupting the production conveyor flow. Korea Ever-Power provides a dimensioned floor plan and utility connection layout drawing for every ZQ110 order to support the Korean customer's facility preparation and civil engineering coordination.

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Q8: Can the ZQ110 produce ABS cosmetic jars across all 10 cavities at 250 ml simultaneously?

Yes. The ZQ110's 1,100 KN injection clamping and approximately 650 g shot weight handle 10-cavity 250 ml ABS production at standard Korean cosmetic jar injection conditions (injection temperature 220–250°C for ABS, mould temperature 40–70°C). ABS requires higher injection pressure than HDPE or PP due to its higher melt viscosity, making the ZQ110's 1,100 KN clamping especially important at 10-cavity configuration to prevent flash at the wide-mouth neck parting line on cosmetic jar formats with large-diameter neck openings. The 4+N barrel zone configuration manages ABS's shorter thermal processing window (ABS degrades if held in the barrel too long at high temperature) by allowing the gate-zone temperature to be held lower than the mid-barrel zones, reducing the heat contribution at the gate end where residence time is longest between cycles.

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Q9: When should a Korean factory choose the ZQ135 instead of the ZQ110?

The ZQ135 is the correct choice over the ZQ110 under three specific conditions. First, cavity count: if the production programme requires more than 24 cavities at 10 ml or more than 20 at 30 ml — the ZQ135 reaches 30 cavities at 10 ml. Second, machine class: the ZQ135 adds 6+N barrel zones (versus 4+N on ZQ110), the highest temperature control precision in the ZQ series, suited to the most demanding resin processing requirements at very large shot weights approaching the series maximum. Third, production volume: if the Korean factory's five-year output forecast shows that the ZQ110's ceiling — approximately 66 million 10 ml units per year — will be reached within three years, investing in the ZQ135 at initial commissioning avoids a machine replacement cycle within a short horizon. For the large majority of Korean pharmaceutical IBM operations at large scale, the ZQ110 is the technically correct upper bound; the ZQ135 is the right choice when cavity count requirements exceed 24 at 10 ml or when the highest precision shot weight control is required.

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Q10: What is the typical delivery timeline for an EP-ZQ110 order to a Korean customer?

Standard EP-ZQ110 machine manufacturing time is 65–80 days from confirmed purchase order and initial payment. If a 24-cavity mould set is ordered simultaneously, mould manufacture — including flow simulation, CNC machining, EDM finishing, assembly and the 500-piece trial run — requires 45–60 days and proceeds in parallel with machine manufacture. Sea freight from Korea Ever-Power's facility to Korean ports (Busan or Incheon) adds 7–14 days. Machine foundation preparation (concrete pad with embedded anchor bolts and conduit for utility connections) at the Korean site should be completed before machine arrival, as the ZQ110's 15-tonne weight requires a prepared foundation rather than simple floor placement. Installation and commissioning by Korea Ever-Power field engineers requires 4–6 days on-site, followed by 4–6 days of operator training. Total timeline from purchase order to production-ready ZQ110 in a prepared Korean facility: approximately 80–100 days for a standard pharmaceutical bottle format with no non-standard site preparation outstanding.

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