How to Set Up a Pet Bottle Manufacturing Business in Nigeria

As the world invents more and more different devices to manufacture plastics , with increasingly sophisticated requirements, new Plastics bottles  are developed to meet the diversifying needs of industry Innovations and mandated health, safety, and environmental concerns. This inevitably increases complexity in manufacturing and opportunities available. However to succeed in the industry requires

Plastic bottles have become an indispensable part of our daily lives, serving as containers for various beverages, household products, and more. The mass production of these ubiquitous items relies on highly sophisticated industrial processes and specialized equipment. In this article, we will delve into the intricate world of plastic bottle production, exploring the technologies and machinery that make it all possible.

Raw materials Requirement: The major material used is the PET Preforms. The plant has the capacity to produce PET bottles from PET Preforms. Other materials includes bagging nylons.

Machinery requirement:  4 Cavity Semi-automatic PET Blowing machine With Air Compressor,  Chilling System, Standards Bottle Moulds, Spares, 20KVA Generating Set,, Safety equipment, Delivery van

There are currently two methods for the production of PET plastic bottles. One is to use an automatic PET bottle blowing machine to complete all the steps from PET raw materials to formed PET bottles. Another production method is to use a two-step method, first use an injection molding machine to make a PET preform, and then blow the bottle through the mold of the bottle blowing machine. The first method can be produced by a fully automatic blow molding machine, but the cost of the equipment is relatively expensive. Generally, large plastic bottle processing plants will purchase plastic bottles using this method. The two-step method is the method that most companies often use to make plastic bottles.

Extrusion Blow Molding - In extrusion blow molding a round, hollow tube or parison is formed by an extruder. A mold cavity, composed of two halves, closes around the parison and pinches off one end. Compressed air expands the parison to conform against the cold mold cavity walls. When sufficiently cool, the mold opens and the container is removed and trimmed of excess plastic or flash. Flash, a basic characteristic of extrusion blow molding, is formed when the parison is pinched off by the mold. Since most resins can be reprocessed, the flash is not wasted but is used as "regrind."Wall distribution, thickness, and weight can be controlled by parison programming. While the parison is extruded, programming changes in the relation of mandrel and die can be used to shift material from heavier, stronger areas to lighter, weaker areas. This method aids significantly in maximizing container performance and minimizing container weight and cost.

Injection Blow Molding - The process of injection blow molding (IBM) is used for the production of hollow plastic objects. Injection blow molding is performed in basically three stages. At the first stage, melted plastic is injected into a mold cavity to produce a preform parison. The preform is shaped like a test tube, but with a molded screw finish at the top. The preform is then transferred to the second, blow-molding stage. Air is blown through a core pin to expand the preform against a cold mold cavity. The container is then transferred to the third station for ejection.  Two main types of processes exist:

One-step injection molding – the melted polymer is injected into the final shape of the container in a cold mold, it's then released.

Two-step injection molding – the first step in the injection of melted plastic in a mold, resulting in the creation of a preform. The cold preform is then taken onto another machine, enclosed in a mold, heated, stretched with a pin to reach the desired length and then blown in the shape of the chosen mold.

Stretch Blow Molding - Stretch blow molding uses either the injection or extrusion blow molding process as a basic foundation. In either case, a preform parison is molded and then transferred to a blow molding cavity. The parison is stretched biaxially during blow molding to orient and align the molecules. This orientation improves the gas barrier, stiffness, clarity and impact strength of the container. As a result, containers can be reduced in weight.Resins which can be stretch blow molded include PET, PVC and Polypropylene. PET has by far the most common use in carbonated beverage containers.

Injection Molding - Injection molded containers can be straight sided or tapered, narrow or wide mouth shapes such as jars, tubs, and vials. Material is injected into a cavity where pressure forces the resin to conform to the mold body. Containers are capable of holding to a tighter dimensional tolerance, and are more uniform in wall distribution. A wide variety of resins can be processed via the injection molding process, the most popular being polypropylene, styrene, and polyethylene.

Multi-Layer Bottles ---- Co-Extrusion - The newest of bottle blowing technology, co-extruded multi-layered bottles bond various plastic resins together with tie layers to produce bottles with barrier and heat-stable qualities suitable for use with hot-filled, hermetically sealed food products. Currently EVOH (ethylene vinyl alcohol) is used as the central layer because of its barrier properties. Polypropylene or polyethylene is used as the inner and outer walls because of their heat tolerance and clarity.The hot-fill process creates a vacuum which will draw in the side walls of a plastic container. This effect must be compensated for in bottle design, either by using an oval shape which will cloak the indentation or by employing strengthening ribs or panels in a round bottle design.Possible applications include: juices, sauces, jams, toppings, mayonnaise, and pickled products.

How to make PET plastic bottles?

1. First, heat the PET raw material to melt it into a molten state, and then put it into the tubular mold of the PET preform making machine. The PET has the same shape as the mold called a parison, and after the system cools, the parison is cut to the correct length.

2. Heat the prepared preform and put it into the mold of the blow molding machine. A steel rod is placed inside the preform and high pressure air is blown to stretch the preform into the shape of the mold.

3. After blow molding, the bottle is quickly cooled and removed from the mold.

4. There may be some excess material seepage during the production process, so trimming is required.

5. The trimmed PET bottle is the bottle that is often used in our daily life.

Startup Capital: The total production Machinery cost is about 8 million Naira, Excluding Cost of Generating set and Delivery Van. Working capital is projected for 42million Naira which can however be higher depending on the financial capacity of the promoter. Gross margin from the plant is projected at 15 million Naira and profit before tax about 8 and 10 million Naira in the first and second year respectively. Payback is within 24 months.

The demand for PET plastics is estimated to rise at about seven percent (7%) annually over the next ten (10) years. With the growing demand for carbonated soft drinks, water and edible oil, PET Preform bottles are also increasing in demand.

The production of plastic bottles on an industrial scale is a marvel of modern engineering and automation. From the careful preparation of raw materials to the precision molding, inspection, and packaging, the entire process is a testament to the integration of technology and innovation. As we continue to rely on plastic bottles for various purposes, the industrial methods described herein ensure efficiency, consistency, and the ability to meet the ever-growing demand for this ubiquitous packaging solution.

Get our Practical Training guide on how to set up a lucrative Pet Bottle Manufacturing Business in Nigeria. The Plant will have the total installed output capacity of 24,000 PET bottles Blowing Capacity per day working for 8 hours daily and 320 days in a year. However production commences at 80% of the installed capacity in the first year and increase thereafter until full production capacity is achieved. The Plant will handle PET Bottles Blowing for clienteles for the 500ml, 750ml and the 1,500ml Plastics types.

The Plant has been designed to use compact and cost efficient PET blowing Machinery originating  from China. The expertise for the plant are available locally. The detailed and comprehensive report according to scale of production cover can be made available to you on request. It will cover all the aspects of the project, from analyzing the market, confirming availability of various necessities such as plant & machinery, raw materials, manufacturing techniques and forecasting financial aspects by estimating the cost of raw material, formulating the income statement, balance sheet and cash flow.

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