사출 블로우 성형
충치 개수 선택 가이드

1단계 — 필수 연간 판매량

계절별 성수기 완충량을 포함하여 연간 필요량을 산정합니다. 한국 소매점의 판촉 수요 및 생산 설비 유지 보수 가동 중단 시간 완충량을 고려하여 기본 연간 생산량에 15~20%를 추가합니다.

2단계 — 한국 공장 근무 시간표

한국의 2교대 근무는 하루 14시간 생산근무 × 250일 생산일수 = 연간 3,500시간입니다. 한국의 3교대 근무는 하루 21시간 생산근무 × 250일 생산일수 = 연간 5,250시간입니다. 한국의 노동 여건상 3교대 근무가 가능한 경우가 아니라면 2교대 근무를 기준으로 계획을 수립하십시오.

3단계 — 충치 개수 계산 공식

4단계 — 활용도 점검

N 값을 다음으로 사용 가능한 ZQ 캐비티 개수로 반올림합니다. 기계 활용률(V_annual ÷ (N × 793/hr × 3,500 h))이 65%와 85% 사이인지 확인합니다. 65% 미만이면 캐비티 개수를 줄여서 다운그레이드합니다. 90% 초과이면 캐비티 개수를 늘려서 업그레이드합니다.

입력

V = 40,000,000
T = 4.0초 · E = 0.88
H = 3,500시간

계산

N = 40M ÷ (793 × 3,500)
N = 4천만 ÷ 2,775,500
N = 14.4 → 20으로 반올림

결과

20개 캐비티의 ZQ80
생산능력: 연간 5540만 개
이용: 72% ✓

헤드룸

연간 1,540만 대 이상
성장 가능
새 기계 없이

클램핑력

플래튼 크기

샷 웨이트

ZQ 범위

400~1,350킬로뉴턴

ZQ40 → ZQ135 클램핑 범위

핵심 차원

> 60mm

플래튼 제한이 처음 발생하는 본체 직경

위험 형식

> 1.0 mm

500ml에서 벽이 샷 제한에 가까워지고 있습니다.

최대 사출 클램핑력(KN)을 사출 압력에서의 캐비티당 투영 면적으로 나눈 값입니다. 10ml HDPE 제약 프리폼의 경우, 캐비티당 클램핑 요구량은 약 35~45KN이며, ZQ40(400KN)에는 9개, ZQ135(1,350KN)에는 30개의 캐비티를 사용할 수 있습니다.

ZQ 터릿 플래튼은 사출 금형의 최대 설치 공간을 물리적으로 제한합니다. 캐비티 개수 또한 플래튼 상의 기하학적 배열에 의해 제한되는데, 인접한 캐비티 사이에는 냉각 채널과 금형 구조적 안정성을 확보하기 위해 충분한 중심 간격이 있어야 합니다.

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.

3학년 목표

< 25M

→ ZQ60 · 14 캐비티

30.8M 시가총액 · 81% 활용률

3학년 목표

25~38개월

→ ZQ80 · 20 캐비티

4400만 시가총액 · 57~86% 활용률

3학년 목표

38~50개월

→ ZQ110 · 24 캐브

5280만 시가총액 · 72~95% 활용률

3학년 목표

> 50M

→ ZQ135 · 30 캐비티

6600만 시가총액 · 76%+ 활용률

IBM 캐비티 수를 늘려도 사이클 시간이 증가하지 않는 이유는 무엇입니까?

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.

기계의 한계치에 근접하여 캐비티 개수가 최대화될 때 IBM 품질에는 어떤 변화가 발생합니까?

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 ZQ 시리즈 머신에서 동일한 머신으로 서로 다른 시점에 서로 다른 캐비티 개수를 설정하여 작업을 수행할 수 있습니까?

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 시리즈 이중 유압 시스템은 ZQ80 이상 모델의 캐빈 개수 계획에 어떤 영향을 미칩니까?

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 금형의 캐비티당 비용은 얼마이며, ZQ 모델에 따라 어떻게 확장됩니까?

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.

한국 제약 공장과 생활화학 공장의 IBM 활용률 적정 범위는 어떻게 될까요?

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 사출 블로우 성형기 ZQ40부터 ZQ135까지의 범위는 스타트업 제약 회사의 9개 캐비티부터 국가 공급 제약 및 소비재 회사의 30개 캐비티에 이르기까지 한국 IBM의 모든 캐비티 수 요구 사항을 충족하며, 제안된 장비와 캐비티 수가 향후 5년간의 계획 기간 동안 70~85% 범위의 목표 활용률을 달성함을 검증합니다.