Sabel Plastics has the courage to challenge the limits of blow molding. Two years ago, a research and design consulting company based in Ohio used a 5kg PET preform to make a large stretch blown PET product, one of the largest stretch blown PET products in the industry. Now, Sam Belcher, who entered the Plastic Hall of Fame, led Sabel to develop the industry's smallest injection blow molded PET container.

This direct-sale single-vial will be commercialized in the second half of 2008. The bottle has a neck diameter of 6mm and a weight of 1.3g. Belcher has participated in the details of many unique plastic technologies. He acknowledged difficulties in finding technical partners for the project because most of them believed that this could not be accomplished.

The main challenge in the production of this miniature bottle is that the micro-core rod concentricity is within 0.05 mm. To this end, Broadway manufactured a 5.36mm diameter metal rod and applied a diamond/PTFE coating to increase lubricity to facilitate the removal of the core rod from the bubble.

After several modifications to the design of the product, the Abramo branch of the mold manufacturing company Big 3 Precision finally determined a patented pillow design to allow the bottle to be squeezed and shunted. The bottle is 0.56mm thick and uses DAK Americas PET resin. This kind of dose bottle has a single-layer structure and can effectively block oxygen. The bottle capacity is 30 ml.

Belcher did not disclose the manufacturer of the all-electric injection blow molding machine used in the project. This multi-chamber device has a special air filtration system that enables it to be used in the production of clean rooms. Other features of the aircraft include: a 762mm diameter trigger bar, nickel plated template, and water lines in the template.

The difficulty in manufacturing such small bottles is the control of injection volume. The product has a molding cycle of 10 to 12 seconds. Belcher hopes to produce 40 million such clear or colored bottles each year.

The occlusal cap is a LDPE injection moulding and it is a big challenge due to its small size. The 0.1 g cap is fitted with a 45° pipe to the cap to make this cap design unique. This tube is 25.4mm long and has a 0.64mm diameter opening at the end and is sealed with ultrasonics. The user twists the end of the tube to allow the liquid in the bottle to flow out. Currently, this type of injection-blow micro PET bottle with a special lid is undergoing final application testing.

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