IBM Machine in Brazil:
Zandei ZQ80 — 120ml Round & Square HDPE Bottle Case Study

Round Mould Set

12 cavities

S136 stainless injection cavity, H13 core rod, P20 blow mould. Round cross-section at 1:1 preform-to-blow circular ratio. Korea Ever-Power standard ZQ80 round IBM mould geometry for Braskem HDPE grade

Square Mould Set

10 cavities

Identical injection cavity and core rod to round set. Square blow mould cavity at 1.15:1 blow ratio deviation from circular — HDPE preform inflates to square cross-section at ZQ80 blow pressure 7.5 bar. Corner wall thickness managed by Korea Ever-Power blow mould corner radius design

Changeover Time

45–60 min

ZQ80 changeover from 12-cavity round to 10-cavity square mould set: blow mould set swap (injection cavity and core rod unchanged, only blow mould changed), process recipe recall from ZQ80 HMI, 10 startup shots per cavity inspection

Zandei Schedule

4:1 ratio

Zandei Brazilian brand customer volume split: approximately 4:1 round to square orders. ZQ80 runs round format 4 days/week and square format 1 day/week, matching Zandei’s São Paulo weekly production schedule to Brazilian brand customer rolling order pattern

Q 01

How does ZQ80 achieve square cross-section IBM on HDPE without wall thinning at corners?

Square HDPE IBM on Korea Ever-Power ZQ80 is achieved through Korea Ever-Power’s blow mould corner geometry design that manages the uneven blow ratio around the square cross-section. In a square 120ml HDPE IBM bottle, the blow ratio from circular preform to square blow cavity varies between the flat faces (lower blow ratio, thicker wall) and the corners (higher blow ratio, thinner wall) of the square cross-section. Without corner geometry compensation, square HDPE IBM corners become excessively thin (below minimum ESCR wall specification) while flat faces are over-weight. Korea Ever-Power’s ZQ80 square blow mould cavity design compensates for corner thinning through two mechanisms: corner radius design — the square blow mould corner radius is set at 4-6mm (not sharp 90-degree corner) to reduce the blow ratio differential between face and corner, distributing wall thickness more evenly around the square cross-section; and core rod position offset — Korea Ever-Power’s blow mould pre-blow positioning allows slight HDPE preform asymmetric inflation initiation that biases material toward corner positions before the main blow pressure fully inflates the square cavity. The outcome at Zandei’s ZQ80: square 120ml HDPE IBM corner wall measured at 0.75-0.85mm versus flat face wall at 0.95-1.10mm — a wall ratio of approximately 1:1.25 between corners and faces, within Korea Ever-Power’s ±30% wall variation specification for square HDPE IBM and above the minimum 0.7mm ESCR wall for Braskem HDPE GM9450F at Zandei’s Brazilian cosmetic formulation ESCR requirement.

Q 02

Can Zandei use Braskem’s bio-based green HDPE (I’m green) for IBM on ZQ80 for Brazilian sustainability branding?

Yes — Braskem’s bio-based HDPE (marketed as SHA7260, the bio-based equivalent of GM9450F in green HDPE I’m green range, produced from Brazilian sugarcane ethanol) is IBM-processable on Korea Ever-Power ZQ80 with minor process parameter adjustment. Braskem’s bio-based HDPE SHA7260 (MFR 0.30-0.45 g/10min, similar to GM9450F) has essentially identical polymer molecular structure to fossil-based HDPE — HDPE produced from ethylene derived from sugarcane bioethanol dehydration is chemically identical to fossil-derived HDPE at the polymer level. This means ZQ80 IBM process parameters for Braskem bio-HDPE SHA7260 are nearly identical to GM9450F fossil HDPE settings, with only minor MFR-related adjustments (bio-HDPE may have slightly lower MFR in some lots, requiring 2-3°C barrel front temperature increase to maintain injection fill rate). The sustainability positioning value for Zandei’s Brazilian brand customers using Braskem bio-HDPE IBM: Braskem issues certificates of analysis confirming bio-based carbon content (>92% bio-based carbon by ASTM D6866 measurement) for each SHA7260 production lot — Zandei’s Brazilian cosmetic brand customers can reference Braskem’s bio-HDPE certificate in their product sustainability claims (carbon-neutral or bio-based packaging) for Brazilian and Latin American green retail market positioning. The cost premium for Braskem bio-HDPE over fossil HDPE is approximately 15-25% at Brazilian polymer distributor pricing — Zandei charges Brazilian brand customers a corresponding packaging sustainability premium for bio-HDPE IBM containers, which premium cosmetic brands at Drogaria São Paulo and Sephora Brazil accept for sustainability-positioned products.

Q 03

What hot-stamp and decoration options does Zandei offer for ZQ80 120ml HDPE IBM bottles?

Zandei’s 120ml HDPE IBM cosmetic bottle decoration capability for Brazilian brand customers operates through two primary decoration methods applied offline after ZQ80 production. Hot-stamp foil decoration: Zandei operates a 4-head rotary hot-stamp machine at their São Paulo facility, applying metallic foil (gold, silver, rose gold — standard Brazilian prestige cosmetic foil colours) to the 120ml HDPE IBM bottle body at up to 30mm width x 50mm height decoration area per stamp. HDPE IBM surface for hot-stamp requires corona pre-treatment to 44-46 mN/m (slightly higher than PP at 42-44 mN/m due to HDPE’s lower surface energy at 31-33 mN/m untreated) — Zandei’s decoration line includes an inline corona tunnel treater ahead of the hot-stamp machine. Hot-stamp adhesion verification on HDPE IBM: cross-hatch adhesion test per ISO 2409 on corona-treated HDPE IBM surface confirms 0/5 (no delamination) for standard hot-stamp foil at 44-46 mN/m. Pad printing for text and graphic: Zandei’s 2-colour pad printing line handles brand logo, product name, ingredient list and Brazilian ANVISA registration number (Registro ANVISA) for Brazilian cosmetic products required on packaging per ANVISA RDC 615/2022. Two-component polyurethane cosmetic ink on corona-treated HDPE IBM, UV-cured for Brazilian tropical climate shelf stability. Korea Ever-Power’s ZQ80 blow mould design for Zandei includes a defined flat label/decoration panel area on both round (60mm wide, 70mm height) and square (50mm wide, 70mm height) 120ml HDPE IBM blow cavity geometry, providing Zandei’s decoration team with a consistent flat surface for hot-stamp and pad print registration accuracy across ZQ80 production runs.

Q 04

How does Brazil’s IPI tax on cosmetic packaging affect Zandei’s IBM container pricing?

Brazil’s IPI (Imposto sobre Produtos Industrializados) applies to cosmetic product packaging at the applicable NCM (Brazilian customs classification) rate for plastic containers. Zandei’s 120ml HDPE IBM cosmetic bottles are classified under Brazilian NCM 3923.30.00 (plastics articles for the conveyance or packing of goods — demijohns, bottles, flasks, and similar articles) at the applicable IPI rate. IPI for NCM 3923.30.00 plastic containers destined for cosmetic product filling is zero-rated (IPI = 0%) for containers sold as industrial inputs to cosmetic manufacturers — Zandei sells IBM containers to Brazilian cosmetic brand customers (CNPJ registered manufacturers) as B2B industrial supply, not retail consumer product, qualifying for the IPI zero-rating on cosmetic packaging material supply. Brazilian ICMS (state VAT) on Zandei’s IBM container supply is the primary indirect tax applicable to Zandei’s IBM container invoice — ICMS rate varies by Brazilian state (12% for São Paulo inter-state supply, 4% for Brazilian simplified tax regime — Simples Nacional if Zandei qualifies). Korean ZQ80 import tax (II at 14% base rate, recoverable as import IPI credit by Zandei if IBM container sales generate IPI output) is managed by Zandei’s Brazilian customs consultant for ZQ80 import tax credit recovery. Korea Ever-Power recommends Brazilian IBM machine buyers consult a Brazilian tax consultant (escritório de contabilidade fiscal) for current IPI/ICMS treatment of ZQ80 IBM machine import and IBM container supply under Brazilian indirect tax rules before ZQ80 investment finalisation.

Q 05

What is Korea Ever-Power’s after-sales service model for Zandei’s ZQ80 in Brazil?

Korea Ever-Power provides after-sales support for Zandei’s ZQ80 in Brazil through a South American regional service model. Brazil authorised service agent: Korea Ever-Power maintains a Brazil authorised service agent in São Paulo with trained ZQ80 maintenance engineers covering São Paulo, Rio de Janeiro and Southern Brazil ZQ80 customer locations. The São Paulo agent provides Zandei with 6-12 hour emergency on-site response for ZQ80 critical production failures during Brazilian business hours. Brazil spare parts consignment: Korea Ever-Power’s São Paulo service agent holds ZQ80 Brazil consumable spare parts (injection cylinder hydraulic seal kit, blow cylinder seal kit, barrel heater bands, HMI touchscreen replacement unit) for same-day or next-day delivery to Zandei’s São Paulo facility. Brazil spare parts import logistics: replacement parts from Korea direct to Zandei via DHL Express São Paulo for non-consignment parts, typically 4-6 business days Korea to São Paulo including Brazilian customs clearance with Korea Ever-Power’s commercial invoice and HS code documentation for Brazilian Receita Federal (customs authority) swift release. Remote VPN service: Korea Ever-Power Ansan-si engineers connect to Zandei’s ZQ80 HMI via VPN remote service during Korean morning hours (07:00-09:00 KST aligns with 19:00-21:00 São Paulo time — outside Zandei’s production shift but available for after-hours process troubleshooting review). Annual preventive maintenance: Korea Ever-Power’s São Paulo service agent performs Zandei’s ZQ80 annual preventive maintenance at Zandei’s facility, with Korea Ever-Power Ansan-si engineer participating remotely for complex ZQ80 hydraulic system or mould calibration procedures requiring factory-level technical authority.

Q 06

Can ZQ80 produce 80ml HDPE IBM alongside 120ml for Zandei’s Brazilian travel-size cosmetic range?

Yes — ZQ80 handles 80ml HDPE IBM at 14-16 cavities (higher cavity count due to smaller preform weight at 80ml), producing approximately 11,000-12,500 bottles/hour at 4.0-4.2s cycle time. Zandei has identified 80ml travel-size HDPE IBM (round and square, matching 120ml brand shape families) as the next format addition to the ZQ80 mould library for Brazilian travel retail and airline amenity kit customers. ZQ80 80ml HDPE IBM mould changeover from 120ml: blow mould set change only (same injection cavity and core rod at shared 24/410 neck specification); ZQ80 process recipe adjustment for 80ml (shorter injection fill, reduced shot size from 142g 12-cavity to ~96g 16-cavity at 80ml format). Korea Ever-Power manufactures 80ml HDPE IBM mould sets compatible with Zandei’s existing ZQ80 injection cavity and core rod used for 120ml production — shared neck tooling between 80ml and 120ml IBM formats reduces Zandei’s mould investment for the 80ml expansion programme by eliminating duplicate injection cavity and core rod tooling costs. Zandei’s Korean ZQ80 multi-format HDPE IBM programme (80ml, 120ml round, 120ml square) from a single machine provides Zandei’s São Paulo facility with a complete Brazilian cosmetic travel-to-standard size HDPE IBM container range from one ZQ80 investment — addressing the full Brazilian cosmetic brand customer format requirement from 80ml travel retail through 120ml standard retail from domestic IBM production.