Enjeksiyon Şişirme Kalıplama
Çürük Sayısı Seçim Kılavuzu

ADIM 1 — GEREKLİ YILLIK HACİM

Mevsimsel zirve tamponunu da dahil ederek yıllık olarak gereken birim sayısını belirleyin. Kore perakende promosyon talebi ve üretim bakım duruş süresi tamponu için yıllık temel hacme 15–20% ekleyin.

ADIM 2 — KORE FABRİKASINDA VARDİYA SAATLERİ

Kore'de 2 vardiya sistemi = günde 14 verimli saat × 250 üretim günü = yılda 3.500 saat. Kore'de 3 vardiya sistemi = günde 21 saat × 250 gün = yılda 5.250 saat. Kore'deki işgücü koşulları 3 vardiya sisteminin uygulanabilirliğini teyit etmedikçe, planlama temelinde 2 vardiya sistemi kullanılmalıdır.

3. ADIM — ÇÜRÜK SAYISI FORMÜLÜ

ADIM 4 — KULLANIM KONTROLÜ

N değerini bir sonraki kullanılabilir ZQ boşluk sayısına yuvarlayın. Makine kullanımının = V_yıllık ÷ (N × 793/saat × 3.500 saat) değerinin 65% ile 85% arasında olduğunu doğrulayın. 65%'nin altındaysa: daha az boşluklu bir modele geçin. 90%'nin üzerindeyse: daha fazla boşluklu bir modele geçin.

GİRİŞ

V = 40.000.000
T = 4,0 s · E = 0,88
H = 3.500 saat

HESAPLAMA

N = 40M ÷ (793 × 3.500)
N = 40M ÷ 2.775.500
N = 14,4 → 20'ye yuvarlayın

SONUÇ

20 boşluklu ZQ80
Kapasite: 55,4 milyon/yıl
Kullanım: 72% ✓

BAŞ MESAFESİ

+15,4 milyon adet/yıl
büyümeye uygun
yeni makine olmadan

Sıkıştırma Kuvveti

Baskı Plakası Boyutu

Saçma Ağırlığı

ZQ Serisi

400–1.350 KN

ZQ40 → ZQ135 sıkıştırma aralığı

Ana Boyut

> 60 mm

Plaka sınırlarının ilk olduğu gövde çapı

Risk Format

> 1,0 mm

Duvar 500 ml'de atış limitine yaklaşıyor

Enjeksiyon basıncında, her bir boşluk için öngörülen alana bölünen maksimum enjeksiyon sıkıştırma kuvveti (KN). 10 ml'lik bir HDPE farmasötik ön kalıpta, her bir boşluk için gereken sıkıştırma kuvveti yaklaşık 35-45 KN'dir; bu da ZQ40'ta 9 boşluğa (400 KN) ve ZQ135'te 30 boşluğa (1.350 KN) olanak tanır.

ZQ taret plakası, enjeksiyon kalıbının maksimum kapladığı alanı fiziksel olarak sınırlandırır. Boşluk sayısı ayrıca plaka üzerindeki geometrik düzenlemeyle de sınırlıdır; boşluklar arasında soğutma kanallarına ve bitişik boşluklar arasında kalıp yapısal bütünlüğüne izin verecek yeterli merkezden merkeze mesafe olmalıdır.

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. YIL HEDEFİ

< 25M

→ ZQ60 · 14 kav

30,8 milyon kapasite · 81% fayda.

3. YIL HEDEFİ

25–38M

→ ZQ80 · 20 kav

44,0M kapasite · 57–86% fayda.

3. YIL HEDEFİ

38–50M

→ ZQ110 · 24 kav

52,8 milyon sermaye · 72–951 TP3T fayda.

3. YIL HEDEFİ

> 50 milyon

→ ZQ135 · 30 kav

66,0 milyon kapasite · 761 TP3T+ fayda.

IBM boşluk sayısının artırılması neden işlem süresini artırmaz?

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.

Makinenin çalışma sınırına yakın maksimum boşluk sayısına ulaşıldığında IBM kalitesine ne olur?

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.

Bir IBM ZQ serisi makine, aynı makine üzerinde farklı zamanlarda farklı sayıda boşluk işlemi gerçekleştirebilir mi?

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 serisi çift hidrolik sistem, ZQ80 ve üzeri modellerde kalıp sayısı planlamasını nasıl etkiler?

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 kalıbının boşluk başına maliyeti nedir ve ZQ modeliyle karşılaştırıldığında nasıl bir ölçeklendirme gösterir?

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.

Kore ilaç fabrikaları ile Kore ev kimyasalları fabrikaları için doğru IBM kullanım aralığı nedir?

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 enjeksiyon şişirme kalıplama makinesi ZQ40'tan ZQ135'e kadar olan ürün yelpazesi, Kore'deki IBM'in başlangıç ​​aşamasındaki ilaç endüstrisindeki 9 kavite sayısından, ulusal çapta ilaç ve hızlı tüketim malları sektöründeki 30 kavite sayısına kadar olan tüm kavite sayısı gereksinimlerini karşılayarak, önerilen makine ve kavite sayısının 5 yıllık planlama ufkunda -85% aralığında hedef kullanım oranını sağladığını doğrulamaktadır.