Pneumatic Solution ensures Model Bottles

Controlled blow moulding process reduces material and energy requirements while optimising PET bottle formation. 

Controlled blow moulding process
  • Client

    a Aventics India Pvt Ltd

  • Services

    Valves, actuators, manifolds, etc.

  • Technologies

    Pneumatic automation

  • Dates



With Aventics’ latest pneumatic solution, a world first, users can now monitor the pre-blow moulding process in the production of PET bottles online, in real time, and immediately make any necessary adjustments. This results in reduced material and energy consumption during high-throughput PET bottle production. For the first time, PET bottle formation can now be controlled and adjusted during the blow moulding process.

With this new solution based on proportional technology, Aventics is entering uncharted technological territory. In collaboration with a major filling company, the pneumatics specialists performed extensive research on the blow moulding process. By combining a proportional valve, control electronics, and software, the solution records the actual values occurring during the process and compares them with the set points.

The new solution is intended for applications in the pre-blowing process. The set points for this step can either be stored in the electronics or transmitted via all common real time Ethernet protocols and fieldbuses. During a blowing period of around 200 milliseconds, enough control cycles are available to precisely control bottle formation. This allows process technicians to intervene as needed, for example to reduce material consumption and fine-tune the formation of the bottle wall. Additional energy savings are possible by lowering the pressure level or reducing the furnace temperature.

Process data taken from the analysis can be used to derive continual improvements. At the same time, quality documentation is carried out in order to safeguard and track the process. In addition, trend analyses of the data enable the detection of wear before a failure can occur. Condition monitoring notifies maintenance early on to be able to carry out the necessary work in planned maintenance breaks.

The electro pneumatic solution also meets new requirements in bottle production resulting from the trend towards more and more complex PET bottle shapes and smaller batches. As a software-based solution, the bottle formation process can be changed easily, without any mechanical alterations, and specific to each blowing station on the machine. The software can also automatically control process events, for example reaching the yield point and target bottle volume, according to specifications and keep them constant provided no wear limits have been reached. Once saved, parameters for a bottle type or specific material can be opened and activated at any time, significantly reducing waste during start of production. In close collaboration with product designers, the developers at Aventics validated numerous sample settings during the pilot production phase of new bottles.

Aventics is one of the world’s leading manufacturers of pneumatic components, systems, and customer-specific applications. The pneumatic engineering company provides products and services for industrial automation, while additionally focusing on the sectors of commercial vehicles, food and beverage, railway technology, life sciences, energy, and marine technology. By integrating electronics, the use of innovative materials and prioritising trends such as machine safety and the Internet of Things, Aventics is a pioneer in applied and environmentally-friendly solutions. The Aventics Group has received multiple certifications, including ISO 9001 and ISO/TS 16949 for quality, ISO 50001 for energy management, and ISO 14001 for environmental management.

Contact: S V Satyanidhi, Aventics India Pvt Ltd, Bangalore. Tel: 080-67727818. Mobile: +91 9538234257. Email:

Caption: With Aventics’ newly developed pneumatic solution PET bottle formation can be controlled and adjusted during the blow moulding process. (Photo: copyright Aventics)