射出ブロー成形
虫歯の数 選択ガイド

ステップ1 — 必要な年間販売量

季節的なピーク時のバッファを含めた年間必要生産量を算出する。韓国の小売業における販促需要と生産設備のメンテナンスによるダウンタイムのバッファとして、基本年間生産量に15～20%を加算する。

ステップ2 ― 韓国工場の勤務時間

韓国の2交代制は、1日14時間×250日＝年間3,500時間です。韓国の3交代制は、1日21時間×250日＝年間5,250時間です。韓国の労働状況から3交代制の実施が確定しない限り、計画の基準は2交代制とします。

ステップ3 — 虫歯数計算式

ステップ4 — 利用状況の確認

Nを次の利用可能なZQキャビティ数に切り上げます。機械稼働率 = V_annual ÷ (N × 793/時 × 3,500時間) が65%～85%の間であることを確認します。65%未満の場合は、キャビティ数を減らしてダウングレードします。90%を超える場合は、キャビティ数を増やしてアップグレードします。

入力

V = 40,000,000
T = 4.0 秒 · E = 0.88
H = 3,500時間

計算

N = 40M ÷ (793 × 3,500)
N = 40M ÷ 2,775,500
N = 14.4 → 20に切り上げ

結果

ZQ80 20 キャビティ
処理能力：5540万トン/年
利用： 72% ✓

ヘッドルーム

年間1540万台以上
成長のために利用可能
新しい機械なしで

締め付け力

プラテンサイズ

ショット重量

ZQシリーズ

400～1,350 kN

ZQ40 → ZQ135 クランプ範囲

主要寸法

60mm以上

プラテンが最初に制限する本体直径

リスクフォーマット

1.0 mm以上

壁は500mlでショット限界に近づいています

最大射出型締め力（KN）を、射出圧力時のキャビティごとの投影面積で割った値。10 mlのHDPE医薬品プリフォームの場合、キャビティごとの締め力要件は約35～45 KNであり、ZQ40（400 KN）では9キャビティ、ZQ135（1,350 KN）では30キャビティを成形できる。

ZQタレットプラテンは、射出成形金型の最大設置面積を物理的に制限します。また、プラテン上の幾何学的配置によってキャビティ数も制限されます。隣接するキャビティ間に冷却チャネルと金型構造の完全性を確保するためには、キャビティの中心間隔を十分に確保する必要があります。

The screw injection unit has a maximum shot weight per cycle — total HDPE or PP injected across all cavities simultaneously. At large container formats with heavy wall, total shot weight may exceed the ZQ model’s rated barrel capacity before clamping force or platen area is fully utilised.

3年目の目標

25M未満

→ ZQ60 · 14騎兵

3080万の容量・81%の利用率。

3年目の目標

25～38歳男性

→ ZQ80 · 20騎兵

4400万キャップ · 57～86%利用率

3年目の目標

38～50M

→ ZQ110 · 24騎兵

5280万キャップ · 72～95%利用率。

3年目の目標

5000万以上

→ ZQ135 · 30騎兵

6600万の容量・76%以上の利用率。

IBMキャビティ数を増やしても、なぜサイクルタイムは増加しないのでしょうか？

IBM’s 4-second cycle time is determined by the longest sequential process step across the 3 stations — typically the blow cooling dwell at Station 2 for HDPE pharmaceutical thin-wall containers. Adding cavities increases the number of simultaneous operations at each station but does not lengthen any individual station’s process time, because all cavities at a given station operate simultaneously (they are all mounted on the same platen that closes and opens together). A 9-cavity mould at ZQ40 and a 30-cavity mould at ZQ135 both take approximately the same 4-second total cycle — the platen closes and opens once per cycle regardless of cavity count. The only process factor that changes with cavity count is injection fill time: more cavities means more total shot weight, which may require marginally longer fill time at very high cavity counts on marginal barrel capacities — but Korea Ever-Power’s ZQ series barrel sizing ensures this is not a limitation at the rated cavity counts shown in the reference table.

IBM製品の品質は、キャビティ数を機械の限界付近で最大化した場合、どうなるのでしょうか？

Operating at maximum rated cavity count for a given ZQ model and container format does not inherently reduce quality — Korea Ever-Power’s ZQ series machines are rated at the cavity counts in the reference table under standard Korean pharmaceutical production conditions, meaning these cavity counts are validated production configurations rather than theoretical limits. Quality risk occurs when cavity count exceeds the machine’s rated limit for a format — typically driven by a Korean customer requesting more cavities than the standard configuration to reduce mould investment. At above-rated cavity counts, three quality risk factors emerge: hot runner gate imbalance (more gates at the same manifold pressure produces greater flow variation across the outer versus inner gates of the runner tree); injection clamping margin reduction (less margin against flash at any gate if injection pressure peaks above the per-cavity average); and mould cooling inadequacy (more cavities in the same platen footprint means less cooling channel area per cavity, increasing cycle-to-cycle temperature variation and dimensional variation). Korea Ever-Power does not approve above-rated cavity counts on ZQ series machines — the rated cavity count is the engineering design point verified by Korea Ever-Power’s process engineers at production conditions. Requests for above-rated cavity count at a given format are addressed by recommending the next ZQ model.

IBMのZQシリーズの機械で、同じ機械で異なるタイミングで異なるキャビティ数で加工することは可能ですか？

Yes — this is one of IBM’s key commercial advantages for Korean contract packaging factories. The ZQ machine’s machine parameters (injection pressure, barrel temperatures, blow air pressure, cycle timing) are set independently for each mould set, stored as named production recipes in the ZQ control system, and recalled by the operator when a mould set is changed. A ZQ80 that runs a 20-cavity 10 ml pharmaceutical mould set for two shifts, then changes to a 6-cavity 500 ml shampoo mould set, then changes to a 10-cavity 100 ml cosmetic jar mould set — recalls three separate production recipes and operates at different cavity counts, cycle parameters and material temperatures for each format without reconfiguring any machine hardware. The only hardware change during format change is the three-component mould set (injection mould, blow mould, stripping tool) and, if the material changes, the barrel purge between materials. Korea Ever-Power’s ZQ control system stores up to 99 named production recipes, supporting the multi-format Korean contract packaging operations that represent the majority of Korean IBM commercial production environments.

ZQシリーズのデュアル油圧システムは、ZQ80以上の機種におけるキャビティ数計画にどのような影響を与えますか？

Korea Ever-Power’s dual hydraulic system (standard on ZQ80, ZQ110 and ZQ135) uses two independent hydraulic circuits — one dedicated to the injection phase and one dedicated to the blow and stripping phases — that operate simultaneously rather than sequentially. This parallel operation has two direct effects on cavity count planning. First, it eliminates the pressure cross-contamination between injection and blow circuits that occurs in single-circuit competitor IBM machines: on single-circuit machines, the hydraulic system must fully complete the injection phase before transitioning to blow phase, and residual injection pressure fluctuation can affect the blow air pressure consistency between cavities. At high cavity counts (20–30), this cross-contamination on single-circuit machines produces inter-cavity weight standard deviation of 5–8% — above the ±4% CV% limit for Korean pharmaceutical IBM containers. Korea Ever-Power’s dual hydraulic system produces inter-cavity weight standard deviation of 2–4% at full rated cavity count — within pharmaceutical specification. Second, the dual hydraulic system delivers 20–30% energy saving versus single-circuit machines at equivalent rated cavity count — documented in Korean customer factory energy measurements — because the dual circuit operates each pump at its optimal efficiency point rather than requiring one pump to serve both the high-pressure injection phase and the lower-pressure blow phase alternately. This energy saving compounds with cavity count: at 30 cavities on the ZQ135, the 20–30% energy saving versus a single-circuit 30-cavity competitor machine saves approximately 15,000–25,000 kWh per Korean two-shift year at full utilisation, reducing Korean factory electricity cost by approximately KRW 2.5–4.0M per year per machine.

IBMの金型製造コストはキャビティあたりいくらで、ZQモデルではど​​のように変化するのでしょうか？

IBM mould cost scales with cavity count approximately linearly per cavity for the injection mould and blow mould components — doubling the cavity count roughly doubles the mould cost, though with some fixed cost amortisation for hot runner manifold design and mould base. The per-cavity mould cost for Korean pharmaceutical 10 ml HDPE IBM moulds (S136 stainless steel, pharmaceutical-grade finish) is approximately KRW 2.5–4.0M per cavity for the complete three-component mould set (injection mould + blow mould + stripping tool), meaning a 20-cavity ZQ80 pharmaceutical mould set costs approximately KRW 50–80M and a 30-cavity ZQ135 mould set costs approximately KRW 75–120M. The per-cavity mould cost decreases slightly at higher cavity counts because the hot runner manifold’s engineering cost is fixed regardless of gate count above 12 cavities — the 19th and 20th gate cost less to add than the 1st and 2nd gate on the same manifold. This means that maximising cavity count within a given ZQ model (using all available clamping force and platen area) produces the lowest capital cost per unit of annual capacity, because the additional mould cost per added cavity is less than the machine stepping cost at the ZQ model boundary. Korea Ever-Power provides itemised mould cost estimates at specific cavity counts for Korean customers evaluating the trade-off between higher-cavity same-model moulds and lower-cavity next-model machines.

韓国の製薬工場と家庭用化学工場におけるIBMの適切な利用範囲はどれくらいでしょうか？

Target IBM machine utilisation differs between Korean pharmaceutical and Korean household chemical factories due to their different operational profiles. For Korean pharmaceutical IBM factories, target utilisation is 65–80% at full annual production. Below 65%: capital is underutilised and the per-unit cost of amortising the machine and the KFDA qualification is too high. Above 85%: there is insufficient scheduled downtime for Korean GMP equipment maintenance, KFDA-required periodic process verification, and cavity inspection without affecting the production plan. Korean pharmaceutical IBM machines are also typically dedicated to single-product or single-format production for entire campaigns (weeks to months at a time), reducing the format-change downtime that household chemical IBM machines carry. For Korean household chemical IBM factories, target utilisation is 70–85% across all formats combined, with individual format campaigns of 1–5 production days per format change. Korean household chemical IBM machines can tolerate higher utilisation (up to 85%) because their format change and maintenance windows are planned with more scheduling flexibility than pharmaceutical GMP production — a Korean household chemical IBM machine can be pulled for mould change or maintenance without KFDA notification. Above 90% utilisation on a household chemical IBM machine creates Korean OEM supply risk: Korean national brands require 100% on-time delivery performance from their Korean OEM packaging suppliers, and a machine at 90%+ utilisation has no capacity buffer to absorb demand spikes (Korean promotional events, Korean seasonal launches) without customer service failures. Korea Ever-Power’s pre-order consultation includes a production scenario analysis that maps the Korean customer’s specific annual volume forecast and format portfolio against each ZQ model’s capacity. The full 射出ブロー成形機 ZQ40からZQ135までの範囲は、スタートアップの製薬規模の9キャビティから、全国供給の製薬およびFMCG規模の30キャビティまで、韓国のIBMキャビティ数のあらゆる要件を網羅しており、提案された機械とキャビティ数が、5年間の計画期間にわたって70～85%のゾーンで目標稼働率を達成することを検証しています。