IBM AUXILIARY EQUIPMENT · CHILLER · DRYER · CONVEYOR · AUTO LOADER · KOREA EVER-POWER
IBM Production Line
Peralatan Bantu Guide for ZQ Series
A Korea Ever-Power ZQ series IBM machine requires four auxiliary systems to operate as a complete IBM production line: mould cooling chiller, material drying system, output conveyor, and automatic material loader. Selecting and specifying each auxiliary correctly for the IBM machine model and container format determines production output consistency, container quality and operator reliability. This guide covers each auxiliary system specification for ZQ40 through ZQ135 IBM production line planning.
Auto Loader • ZQ40–ZQ135
Complete IBM Line Specification
KOREA EVER-POWER · ANSAN-SI, GYEONGGI-DO · JULI 2026
IBM AUXILIARY SYSTEM · QUICK SPECIFICATION REFERENCE
MOULD CHILLER
10–18°C
Mould cooling water target: 10-15°C for standard PP/HDPE IBM; 12-18°C for wide-mouth jar IBM. Chiller capacity: 5 kW (ZQ40) to 25 kW (ZQ135). ΔT inlet-outlet ≤2°C at mould
MATERIAL DRYER
PP: 80°C/2hr
Hot-air hopper dryer: PP/HDPE at 80°C for 2hr minimum. PCTG requires dehumidifying dryer at 85°C/4-6hr with dew point ≤−40°C. Dryer capacity: 25kg (ZQ40) to 200kg (ZQ135) per batch
OUTPUT CONVEYOR
Belt width: 200–500mm
Belt conveyor width: 200mm (ZQ40, small bottles) to 500mm (ZQ135, large jars). Belt speed adjustable 5-25 m/min. Conveyor length typically 1.5-3.5m to collection bin or packing station
AUTO LOADER
Vacuum venturi
Vacuum venturi loader transfers dried PP/HDPE pellets from floor-level dryer hopper to ZQ IBM machine throat hopper. Capacity: 30-200kg/hr. Cycle: timed or level-sensor triggered loading to maintain ZQ barrel feed
BAGIAN 01
Mould Cooling Chiller: Selection and Specification by ZQ Model
The mould cooling chiller is the most critical IBM auxiliary unit for container quality — mould cooling water temperature directly controls PP or HDPE crystallisation rate, which determines container wall clarity, dimensional stability and production cycle time. Korea Ever-Power’s ZQ series IBM machines from ZQ40 through ZQ135 require dedicated air-cooled or water-cooled chillers sized to each machine’s mould heat load, mould cooling circuit flow rate and target cooling water temperature range. Using an undersized chiller or facility water supply (above 18°C) instead of a dedicated chiller is the most common IBM production quality problem Korea Ever-Power encounters at new customer installations — producing containers with excessive haze (PP), base deformation (HDPE) and extended cycle time that directly reduces IBM output and profitability.
| MODEL ZQ | CHILLER CAPACITY | FLOW RATE (L/min) | TARGET TEMP (°C) | CHILLER TYPE |
|---|---|---|---|---|
| ZQ40 | 5–8 kW | 8–15 | 10–15 | Air-cooled, single-compressor |
| ZQ60 | 8–12 kW | 12–20 | 10–15 | Air-cooled, single-compressor |
| ZQ60HE | 8–12 kW | 12–20 | 10–15 | Air-cooled or oil-free (pharma) |
| ZQ80 | 12–18 kW | 20–35 | 10–16 | Air-cooled, dual-compressor |
| ZQ110 | 18–28 kW | 30–50 | 10–16 | Air-cooled or water-cooled dual |
| ZQ135 | 25–40 kW | 40–65 | 10–18 | Water-cooled (preferred for ZQ135) |
Critical chiller sizing rule: Korea Ever-Power sizes IBM chillers at 1.5× calculated mould heat load to provide capacity margin for Korean summer ambient temperature (up to 35°C in Korean factories in July-August), mould heat load variation between production formats, and chiller efficiency reduction as ambient rises. An undersized chiller running at full capacity in Korean summer will fail to maintain 10-15°C cooling water, producing out-of-spec containers and forcing reduced cycle speed.
BAGIAN 02
Material Drying System: Hot-Air vs Dehumidifying Dryer
Hot-Air Hopper Dryer (PP/HDPE Standard)
Hot-air hopper dryer is the standard drying auxiliary for PP and HDPE IBM materials on Korea Ever-Power ZQ machines. PP and HDPE are non-hygroscopic polymers that do not absorb atmospheric moisture into the polymer chain — surface moisture from storage humidity is removed by 80°C hot-air circulation at 2 hours minimum residence time in the hopper. Hot-air dryer specification for ZQ40: 25 kg hopper capacity (approximately 2-3 hours PP throughput at ZQ40 production rate), 80°C set temperature, 200 m³/hr air flow. ZQ60: 50 kg hopper, 80°C, 350 m³/hr. ZQ80/ZQ110: 100 kg hopper, 80°C, 500 m³/hr. ZQ135: 150-200 kg hopper, 80°C, 700 m³/hr. Over-drying PP above 4 hours at 80°C or above 100°C causes PP thermal degradation (yellowing, MFR increase) — Korea Ever-Power’s ZQ machine HMI provides dryer set temperature control and overtime alarm to prevent PP over-drying at Korean customer production sites.
Dehumidifying Dryer (PCTG/PC Mandatory)
PCTG, PC and PET are hygroscopic polymers that absorb atmospheric moisture into the polymer chain — requiring a dehumidifying dryer that supplies air at dew point ≤−40°C to remove polymer-bound moisture before IBM processing. Hot-air dryer cannot achieve −40°C dew point supply air and is completely unsuitable for PCTG IBM. Dehumidifying dryer specification for ZQ40 PCTG IBM: 15 kg hopper capacity, 85°C drying temperature, 4-6 hours residence time at −40°C dew point supply air. ZQ60 PCTG: 30 kg hopper, 85°C, 4-6 hours. Dehumidifying dryer investment is significantly higher than hot-air dryer — but is non-negotiable for PCTG or PC IBM: undried PCTG produces IBM containers with surface silver streaks (moisture splay), reduced molecular weight and diminished clarity from polymer hydrolysis during IBM barrel processing. Korea Ever-Power specifies dehumidifying dryer with dual-tower desiccant regeneration at ZQ40 or ZQ60 PCTG IBM machine orders.
BAGIAN 03
Output Conveyor: Design and Integration for IBM Production
Conveyor Belt Width Selection
IBM output conveyor belt width is determined by the maximum container diameter (or jar diameter for wide mouth applications) and the expected containers side-by-side on the belt from multiple-cavity production. Standard Korea Ever-Power conveyor belt widths by ZQ machine and format: ZQ40 (30-100ml small bottles): 200mm belt accommodates 6-10 containers side-by-side from 6-10 cavity ZQ40 production. ZQ60 (100-350ml): 300mm belt. ZQ80/ZQ110 (300-750ml): 400mm belt. ZQ135 (750ml-1L wide mouth jars): 500mm belt. Wide mouth jar IBM conveyors also require a conveyor entry guide rail at the ZQ stripping station to orient jars upright on the belt (jar IBM containers must travel upright; narrow-neck bottles can travel on their sides).
Conveyor Speed and Length
IBM output conveyor belt speed must be high enough to clear containers from the stripping station before the next production cycle deposits new containers, but not so high that containers tip or jam at the collection end. Korea Ever-Power’s standard IBM conveyor speed specification: 8-12 m/min for small-format IBM (ZQ40, 30-100ml bottles) where cycle rate is highest (8-12 containers/cycle × 1 cycle/4s = 2-3 containers/second per belt entry point). 5-8 m/min for large-format IBM (ZQ135, 1L bottles or jars) where lower cycle rate and larger container base area determine belt loading. IBM output conveyor length: 1.5-2.5m for ZQ40/ZQ60 connecting stripping station to collection bin at production operator station; 2.5-3.5m for ZQ80/ZQ110/ZQ135 with additional length for inline quality station integration (weight check, vision check).
BAGIAN 04
Automatic Material Loader: Specification and Operation
Vacuum Venturi Auto Loader Operation
The ZQ IBM machine barrel receives PP or HDPE pellets from a throat hopper mounted directly on the machine barrel feed port. Without an auto loader, an operator must manually refill the throat hopper every 15-60 minutes (frequency depends on ZQ machine throughput and throat hopper volume) — a labour-intensive task that causes intermittent barrel starvation if the operator is occupied with other duties. Korea Ever-Power’s standard IBM auto loader is a vacuum venturi type: a venturi generator (connected to compressed air at 4-6 bar) creates suction that conveys PP/HDPE pellets from the floor-level dryer hopper through a 32-50mm OD flexible hose to the ZQ machine throat hopper. The auto loader is triggered by a level sensor in the ZQ throat hopper: when pellet level drops below the sensor, the venturi activates for a timed loading cycle (typically 10-30s) to refill the throat hopper. The auto loader eliminates manual material loading labour and ensures continuous ZQ barrel feed for unattended IBM production shifts.
Colour Masterbatch Dosing Integration
IBM container colour programmes (opaque white, pigmented PP) require precise masterbatch addition at the ZQ machine throat hopper. Korea Ever-Power integrates a gravimetric masterbatch doser on the ZQ throat hopper alongside the auto loader: the doser weighs masterbatch pellets per shot and adds them to the PP/HDPE pellet stream entering the ZQ barrel at a precisely controlled masterbatch percentage (typically 1.5-3.0% by weight). Gravimetric dosing accuracy of ±0.1% masterbatch addition enables consistent colour (CIE L*a*b* ±2 units) across full production batches without manual masterbatch weighing. Korea Ever-Power specifies the gravimetric doser capacity (doser throughput matched to ZQ material consumption rate at peak production speed) at ZQ machine order for colour IBM programmes at Korean cosmetic and food supplement brand customers.
BAGIAN 05
ZQ Series Auxiliary Equipment Package by Machine Model
COMPLETE AUXILIARY PACKAGE BY ZQ MODEL — PP/HDPE STANDARD IBM
ZQ40 Package
Standard IBM line
Air-cooled chiller 6 kW • Hot-air dryer 25 kg/80°C • Auto loader venturi 30 kg/hr • Belt conveyor 200mm/2.0m • Total auxiliary footprint: 2.5 × 1.2m alongside ZQ40
ZQ60 / ZQ60HE Package
Mid-range IBM line
Air-cooled chiller 10 kW • Hot-air dryer 50 kg/80°C (or dehumidifying dryer 30 kg/85°C for PCTG) • Auto loader 60 kg/hr • Belt conveyor 300mm/2.5m • Footprint: 3.2 × 1.5m
ZQ80 / ZQ110 Package
Large-format IBM line
Air-cooled chiller 20 kW • Hot-air dryer 100 kg/80°C • Auto loader 100 kg/hr • Belt conveyor 400mm/3.0m • Footprint: 4.0 × 1.8m auxiliary zone alongside ZQ80/ZQ110
ZQ135 Package
Max-format IBM line
Water-cooled chiller 35 kW • Hot-air dryer 200 kg/80°C • Auto loader 150 kg/hr • Belt conveyor 500mm/3.5m • Footprint: 5.0 × 2.0m auxiliary zone. External cooling tower required for ZQ135 water-cooled chiller
BAGIAN 06
Factory Layout and Utility Planning for IBM Auxiliary Systems
Korean Factory Utility Requirements
Korea Ever-Power specifies the following utility connections for the complete ZQ IBM auxiliary package at Korean factory installation. Compressed air: 6 bar stable supply at minimum 200 L/min flow for ZQ40 auto loader venturi and blow station; 400 L/min for ZQ60/ZQ110; 600 L/min for ZQ135. Compressed air must be oil-free and filtered to 5 μm for auto loader venturi to prevent oil contamination of the PP/HDPE material transport hose. Electrical supply: dedicated 380-440V three-phase circuit for chiller (separate from ZQ machine circuit — chiller compressor startup surge current is 3-5× running current and must not share the ZQ machine circuit). Water supply for water-cooled chiller (ZQ110/ZQ135 option): 20-35°C tower water at 30-60 L/min, closed-loop cooling tower or facility chilled water header. Floor drain: chiller condensate drain and cooling water circuit drain at auxiliary zone for Korean factory maintenance access.
IBM Production Line Floor Plan
Standard Korea Ever-Power ZQ40 IBM production line floor plan: ZQ40 machine (3.5 × 1.3m footprint) with 1.0m operator access clearance on all sides; chiller positioned behind ZQ40 (0.8 × 0.6m unit) with cooling water piping in floor-level cable duct; dryer hopper on ZQ40 barrel stand or on separate floor stand beside ZQ40 with flexible auto loader hose connection to ZQ40 throat; output conveyor extends from ZQ40 stripping station toward operator collection position or packing table. Total ZQ40 production cell floor area: minimum 5.0 × 3.0m clear. ZQ60 production cell: 6.5 × 3.5m. ZQ135 production cell: 10.0 × 5.5m including cooling tower space. Korea Ever-Power provides AutoCAD floor plan drawing for the Korean customer’s ZQ IBM production cell at machine order stage, enabling Korean factory civil and electrical engineering teams to plan utility installation before ZQ machine delivery.
FAQ TEKNIK
IBM Auxiliary Equipment — Engineering Questions
Pertanyaan 01
Can a single chiller serve multiple ZQ IBM machines at the same Korean factory?
Yes — a single chiller can serve multiple ZQ IBM machines at a Korean factory if the chiller capacity is sized for the combined mould heat load of all ZQ machines running simultaneously, and if the chiller flow rate and cooling water distribution piping is sized to maintain target mould temperature (10-15°C) at each ZQ machine’s mould inlet simultaneously without inter-machine temperature interference. Korea Ever-Power’s multi-machine chiller sizing rule: sum the mould heat load of all ZQ machines at peak simultaneous production, multiply by 1.5 safety factor, and specify a single central chiller or chiller bank at that capacity. A manifolded cooling water distribution system with individual flow control valves and temperature sensors at each ZQ machine mould inlet/outlet ensures each ZQ machine receives target 10-15°C cooling water independent of other machines’ operating conditions. For Korean IBM production facilities with 3-10 ZQ machines of mixed formats (ZQ40, ZQ60, ZQ80), a central chiller bank of 2-3 modules with lead-lag control provides redundancy: if one chiller module requires maintenance, the remaining module(s) maintain cooling supply to Korean IBM production at reduced capacity rather than complete cooling loss. Korea Ever-Power recommends central chiller with manifold distribution for Korean IBM production facilities with 3 or more ZQ machines, providing better economy of scale versus individual chillers per ZQ machine at lower redundancy cost.
Pertanyaan 02
What causes IBM container base deformation and how does the chiller prevent it?
IBM PP container base deformation (inward base panel sinking, base non-flat at room temperature after production) is one of the most common IBM quality problems at Korean factories, and is directly caused by inadequate mould cooling at the base cavity zone of the blow mould. The IBM container base is the last zone inflated during blow pressure stroke — the PP material at the base is the hottest zone in the blow mould cavity at the time of stripping. If the blow mould base cavity cooling is insufficient (cooling water above 16°C, or flow rate too low to cool the base zone within the blow dwell time), the PP base is stripped while still above PP crystallisation temperature (125-135°C for PP homopolymer). The hot base then deforms under atmospheric pressure and gravity during the first 10-30 seconds after stripping, producing the inward sink that is visible on the filled and standing container on the Korean customer’s production packing line. Prevention: Korea Ever-Power’s blow mould base cavity design includes a dedicated base cooling circuit with 8-10mm bore cooling channels surrounding the base pin geometry, supplied at 10-13°C from the IBM chiller. Chiller temperature below 13°C at blow mould base circuit inlet is the critical parameter for PP IBM container base integrity at ZQ40/ZQ60 standard Korean production conditions. Korea Ever-Power’s ZQ machine commissioning engineers verify blow mould base temperature at Korean customer startup, adjusting chiller set temperature and flow rate until base deformation is confirmed absent across all cavities before handing over production to the Korean customer’s production team.
Pertanyaan 03
What happens if PP material is not dried before ZQ IBM production?
Undried PP IBM at ZQ machines produces several container defects whose severity increases with PP surface moisture content and barrel dwell time. At mild undried PP (storage humidity above 70% RH for less than 24 hours without drying): surface moisture vaporises in the barrel to produce small silver streak marks on the IBM container exterior (visible as fine silver lines running parallel to the flow direction on the container body). These silver streaks are a visual defect that causes Korean cosmetic brand customer rejection of the container at incoming QC inspection. At moderate undried PP (high-humidity Korean summer storage without drying): moisture content above 500 ppm produces visible bubble voids in the PP IBM container wall — small internal bubbles that reduce container wall strength and produce hazy spots on the container exterior at Korean retail lighting inspection. At severe undried PP (rain-exposed PP sacks or very high humidity without any drying): water content above 1,000 ppm causes PP hydrolytic degradation in the ZQ barrel (MFR increase, yellowing) and produces IBM containers with severe silver streak, weak wall, and possible short shots where the PP melt does not fill the injection preform cavity completely. Korea Ever-Power’s Korean customer startup training emphasizes PP drying protocol compliance as the highest-priority IBM process control requirement for Korean production teams, providing the dryer set temperature, residence time and material throughput calculation for each ZQ machine and PP grade at Korean commissioning.
Pertanyaan 04
Can the IBM output conveyor integrate with automatic packing line or robot arm for Korean production automation?
Korea Ever-Power IBM output conveyors are designed with automation integration end-points for Korean production line extension beyond the IBM machine. Standard automation integrations available at Korea Ever-Power IBM output conveyor discharge end: checkweigher integration: inline weight-checker (Korea Ever-Power recommends Mettler-Toledo or Korean-equivalent conveyor scale) mounted at conveyor discharge measures each IBM container weight (or batch weight by count), with reject diverter arm to reject out-of-specification containers before packing. Vision inspection integration: inline camera vision system (see S02 IBM vision inspection article) mounted above or alongside the conveyor discharge for neck OD measurement, body surface defect detection and base inspection before Korean brand customer automated packing. Robot pick-and-place integration: a 6-axis robot arm (Korean-market robots: Hyundai Robotics, Doosan Robotics, Fanuc Korea) at the conveyor discharge performs automatic container orientation and tray-packing for high-volume Korean IBM programmes eliminating the manual packing operator position. Korea Ever-Power provides IBM conveyor end-stop and container accumulation table specification for Korean robot pick-and-place integration — the accumulation table allows robot pick rate to be asynchronous from IBM production rate, preventing robot cycle-time constraints from limiting ZQ machine production speed. Full IBM production line automation for Korean brand customers (ZQ machine + conveyor + checkweigher + vision + robot packing) is available as a Korea Ever-Power turnkey IBM line project with single-source project management from machine FAT through Korean factory installation, commissioning and operator training.
Pertanyaan 05
What auxiliary equipment changes are needed when switching from PP to PCTG on the same ZQ40 machine?
Switching a ZQ40 IBM production programme from PP to PCTG requires auxiliary equipment changes in three systems: dryer changeover (critical), chiller temperature adjustment, and conveyor speed reduction. Dryer changeover: the PP hot-air hopper dryer must be exchanged for a dehumidifying dryer with −40°C dew point supply air before PCTG IBM can begin. This requires either a second dehumidifying dryer unit installed alongside the ZQ40 for PCTG programmes (best practice for Korean IBM production facilities running both PP and PCTG regularly), or rental or loan of a dehumidifying dryer for PCTG programme periods. Running PCTG through the PP hot-air dryer produces heavily defective IBM containers (silver streaks, poor clarity, surface bubbles) from undried PCTG hydrolytic degradation. Chiller temperature: PCTG IBM at ZQ40 requires colder mould cooling water (8-12°C versus PP standard 10-15°C) to achieve rapid PCTG solidification in the injection cavity and prevent PCTG preform sticking on the core rod. Korea Ever-Power adjusts ZQ40 chiller set temperature to 8-10°C for PCTG IBM and verifies injection cavity core rod release quality before production. Barrel temperature: ZQ40 barrel temperature profile changes from PP IBM (220-235°C) to PCTG IBM (240-275°C) — barrel heat-up time from PP to PCTG temperature: approximately 20-30 minutes at ZQ40 barrel heating capacity. Korea Ever-Power provides ZQ40 PP-to-PCTG switchover protocol (barrel purge, temperature ramp, dryer changeover sequence) as part of ZQ40 customer training at Korean factory commissioning for customers planning dual-material PP/PCTG IBM programmes.
Pertanyaan 06
Does Korea Ever-Power supply IBM auxiliary equipment as part of the ZQ machine purchase or separately?
Korea Ever-Power offers IBM auxiliary equipment both as part of the ZQ machine package (recommended for new Korean IBM customers establishing first IBM production line) and as separately quoted items (for experienced Korean IBM customers who already have auxiliary equipment from previous IBM line installations or who prefer to source specific auxiliary components locally). Complete ZQ IBM machine package (recommended): Korea Ever-Power quotes ZQ machine + mould set + chiller + dryer (hot-air or dehumidifying as specified) + auto loader + conveyor as a single IBM production line package with integrated installation and commissioning at the Korean customer’s factory. This package approach ensures all auxiliary specifications are matched to the ZQ machine model and IBM container format by Korea Ever-Power’s application engineers, eliminating the risk of mismatched chiller capacity, incorrect dryer type or undersized conveyor that Korean customers occasionally encounter when sourcing auxiliaries independently from local Korean plastic machinery suppliers. Separate auxiliary procurement: Korean IBM customers with existing IBM installations (upgrading from competitive IBM machine to ZQ series, or adding ZQ machines to existing Korean IBM facility) may already have appropriately sized chillers, dryers and conveyors and wish to reuse existing auxiliary equipment with the new ZQ machine. Korea Ever-Power’s Korean sales team will review existing auxiliary specifications against ZQ machine requirements and advise on compatibility before ZQ machine order. Korea Ever-Power installation engineers verify existing auxiliary performance at Korean factory ZQ commissioning and provide recommendations for auxiliary upgrade if performance gaps are identified during startup qualification.
IBM AUXILIARY ENQUIRY · KOREA EVER-POWER
Planning a Complete IBM Production Line?
Korea Ever-Power provides complete ZQ IBM production line packages including chiller, dryer, auto loader and conveyor, with factory layout drawing, utility specification and turnkey installation for Korean and global IBM customers.
Editor: Cxm
