Extrusion blow molding (EBM) is the workhorse process behind most hollow plastic containers that are not made from PET preforms: chemical drums, jerry cans, water tanks, cosmetic jars, pharmaceutical bottles and a long list of industrial hollow articles. Apollo, a Wanplas factory, builds EBM machines as configurable platforms rather than fixed productos. The same base machine can become a single-cavity cosmetic jar line, a four-cavity detergent bottle line, or a twin-station chemical drum line simply by changing the mold, the electrical package and the function modules. This guide explains exactly how to customize an EBM machine so the finished line matches your container, your resin, your local grid and your quality requirements. It walks through mold and cavity design, voltage and PLC options, and the function modules that turn a standard machine into a production tool built around your product. Real Apollo series and representative specifications are used throughout so you can translate the customization options into a concrete machine proposal.
Why Customize an EBM Machine
Customizing an EBM machine means adapting three independent layers of the equipment so the whole system is built around one product family rather than forcing the product to fit a generic machine. The first layer is the mold and cavity design, which decides the container shape, neck finish, wall thickness distribution and how many parts are made per cycle. The second layer is the electrical configuration: voltage, frequency, PLC platform and human-machine interface language, all of which must match your factory grid and your operators. The third layer is the set of function modules such as view stripe, automatic deflash, in-machine leak test and multi-layer co-extrusion, which decide what the machine can do beyond the basic extrude-and-blow cycle.
A machine that is not customized to the product wastes material, slows the cycle and forces manual labor onto the line. A chemical drum producer who runs a single-layer machine when the market requires a barrier layer will fail compliance testing. A cosmetic jar producer who buys a four-cavity mold when one cavity is enough overspends on clamping force and floor space. A buyer in a 60Hz market who receives a 50Hz machine faces transformer costs and motor derating. Customization is therefore not a luxury option; it is the difference between a line that pays back quickly and a line that fights you every shift.
Apollo approaches customization as a configuration exercise on proven platforms. The ABLB series covers containers from 200 milliliters to 20 liters, the ABLD series covers 20 liters to 1,500 liters for drums, tanks and large industrial parts, and the Totalmente eléctrica series covers 200 milliliters to 20 liters with an all-electric, hydraulic-free drive for clean and energy-sensitive plants. Within each series the mold, electrical package and function modules are selected per order, which is why a single series can serve detergent bottles, pharmaceutical jars, lubricant drums and automotive fluid containers without changing the machine structure.
Mold & Cavity Customization: The Heart of the Order
The blow mold is the single most important customized component on an EBM machine. It determines the external shape, the neck finish (the thread and sealing surface), the handle geometry, the surface texture and the number of cavities running in parallel. Because the mold sits in the clamping station and receives the parison, its design also interacts with clamping force, cooling time and cycle time. Getting the mold right is the foundation of every other customization choice.
Cavity Number and Output Relationship
Cavity number is the first decision because it scales output directly. A single cavity makes one container per cycle; a four-cavity mold makes four. But more cavities require a larger clamping platen, more clamping force, a larger parison head and a higher extrusion rate. The practical ceiling for a given machine frame is set by the clamping force and the extruder throughput. Apollo’s ABLB frames are engineered for one to six cavities in the small-container range, while the ABLD frames support single or double cavities for very large parts where one 1,000-liter part already fills the clamping area.
La relación entre las cavidades y la producción no es perfectamente lineal porque el tiempo de enfriamiento crece con el espesor de la pared y el tamaño de la pieza. En un contenedor de 1 litro de pared delgada, el ciclo puede durar unos segundos, por lo que las cuatro cavidades suministran aproximadamente cuatro veces el contador horario; en una cuba de 10 litros de pared gruesa, el ciclo es mucho más largo y el beneficio de añadir cavidades está limitado por el enfriamiento en lugar de por la extrusión. Ése es el motivo por el que una especificación adecuada comienza por el objetivo de producción horaria o anual, y luego trabaja hacia atrás para determinar el número de cavidades que la máquina puede soportar de manera realista.
Mold Material and Cooling Design
Blow molds are typically machined from aluminum for short runs and fast heat extraction, or from steel (often bimetallic or hardened tool steel) for long production runs and abrasive filled resins. Aluminum cools faster and is cheaper to cut, which shortens lead time and cycle, but it wears faster with regrind or glass-filled compounds. Steel lasts far longer and holds tight tolerances on the neck finish but costs more and cools a little slower. Apollo selects the mold material to match the resin and the expected run length, and designs the cooling channels to follow the part contour so wall thickness stays uniform and cycle time stays short.
Cooling is frequently the hidden bottleneck. A mold with poorly placed channels forces the operator to extend the cooling phase, which lengthens the cycle and lowers output. Good mold design puts turbulent-flow cooling directly behind the thick sections, such as the handle and the base, and keeps the neck-cooling separate so the thread is not distorted. When you customize the mold you should therefore specify not only the shape but the expected resin and output, because those inputs drive the cooling layout.
Neck Finish, Surface and Secondary Features
The neck finish must match your cap and filling line. Common finishes include continuous-thread, snap-on, tamper-evident and trigger-spray necks, each with a defined diameter, thread pitch and sealing land. Apollo machines the neck cavity to the cap drawing so the closure seats correctly on the first run. Surface options include high-gloss polish for cosmetic jars, matte texture for grip, and etched logos or measurement scales directly in the cavity. Secondary features such as integrated handles, hanging holes and graduated volume marks are all built into the mold rather than added later.
Mold Customization Specification Table
The table below maps the mold decisions to the effect on the machine and the line, which helps you translate a product idea into a mold specification.
| Decisión del molde | Typical choices | Effect on machine and line |
|---|---|---|
| Cavity number | 1, 2, 3, 4, 6 (small parts) | Scales output; raises clamping force and extruder rate requirement |
| Material del molde | Aluminum, hardened steel, bimetallic | Affects cooling speed, wear life and cost |
| Neck finish | CT, snap-on, tamper-evident, trigger | Must match cap and filler; machined to cap drawing |
| Surface texture | High gloss, matte, etched logo, scale | Customizes brand appearance at no cycle penalty |
| Handle and features | Integrated handle, hole, graduated marks | Built into cavity; affects cooling and wall distribution |
| Cooling layout | Canales turbulentos que siguen contornos | Shorter cycle, uniform wall, less scrap |
ABLB Series Mold & Cavity Reference
The ABLB series is Apollo’s core EBM platform for containers from 200 milliliters up to 20 liters, used for bottles, jars, jerry cans and small industrial vessels. It is offered in several frame sizes, each pairing an extruder with a clamping station sized for a cavity range. Because the series is built as a configurable frame, the mold and cavity count are chosen per order. The table below lists representative ABLB frames and the cavity and container ranges they support; the exact figures are confirmed in the engineering proposal because screw, clamping force and power are matched to the final resin and output.
| Model (representative) | Screw diameter (mm) | Container range | Typical cavities | Clamping force (kN) | Approx. installed power (kW) |
|---|---|---|---|---|---|
| ABLB 55 | 55 | 0.2 – 2 L | 1 – 4 | 50 – 80 | 22 – 30 |
| ABLB 65 | 65 | 1 – 5 L | 1 – 4 | 80 – 120 | 30 – 45 |
| ABLB 75 | 75 | 3 – 10 L | 1 – 3 | 120 – 180 | 45 – 60 |
| ABLB 90 | 90 | 5 – 20 L | 1 – 2 | 180 – 260 | 55 – 75 |
These values are representative of the ABLB platform and illustrate how the frame scales with container size. As the container grows toward 20 liters, fewer cavities fit the platen and the clamping force requirement rises, so the extruder and clamp are sized up together. For a 2-liter detergent bottle, an ABLB 65 with four cavities and a continuous-extrusion head typically delivers the highest output per square meter of floor space. For a 10-liter lubricant jerry can, an ABLB 75 with one or two cavities and a calibrated parison program is the better balance of output and wall control.
When you customize an ABLB machine, the mold cavity count is matched to the screw throughput so the parison is always available when the clamp closes. If the cavities demand more melt than the screw can supply, the cycle stalls waiting for material; if the screw over-supplies, melt accumulates and the head pressure drifts. Apollo sets the screw diameter, L/D ratio and head design together with the cavity count so the line runs at a stable, repeatable cadence.
Voltage & PLC Electrical Customization
The electrical package is the second customization layer and the one most often overlooked until the machine arrives. Every market has a different grid standard, and an EBM machine contains motors (extruder drive, clamp, blow, parison control), heaters (barrel and die head), servo valves and a control system that all assume a specific voltage and frequency. Specifying the wrong electrical standard means transformers, derated motors or, in the worst case, a burned drive.
Voltage and Frequency Options
Apollo configura la máquina para la red nacional del cliente. Los estándares más comunes son 380 a 415 voltios a 50 hertz de tres fases, utilizados en Europa, Oriente Medio, África y la mayor parte de Asia; 220 a 240 voltios u 440 a 480 voltios a 60 hertz de tres fases, utilizados en las Américas; y 200 voltios a 50 o 60 hertz para Japón. Los circuitos de control de modo único se derivan internamente, independientemente de la fuente de alimentación principal, pero las características de la unidad motriz y del calefactor se establecen en la fábrica. Los calefactores, en particular, deben volver a enmoldarse para la tensión correcta, ya que un calefactor de 415 voltios a 480 voltios se sobrecalentará y fallará rápidamente.
| Region / market | Main voltage | Frequency | Apollo configuration note |
|---|---|---|---|
| Europe, Middle East, Africa | 380 – 415 V | 50 Hz | Standard three-phase; heaters and motors matched |
| North America | 440 – 480 V | 60 Hz | Rewound heaters; 60 Hz motor nameplate |
| América del Sur | 220 – 240 V or 380 V | 60 Hz | Confirm local utility before order |
| Japan | 200 V | 50 / 60 Hz | Region-dependent frequency |
| Australia, New Zealand | 415 V | 50 Hz | Standard three-phase |
PLC, HMI and Control Language
The control system is the operator’s daily interface, so its customization matters as much as the hardware. Apollo builds the machine around a mainstream programmable logic controller (PLC) with a touch-screen human-machine interface (HMI). The HMI can be set to English, Spanish, Arabic, French, Russian, Portuguese or other languages, and the recipe management stores multiple container recipes so an operator switches productos by selecting a saved recipe rather than re-entering temperatures and timings. For plants that want remote oversight, Apollo configures remote monitoring so the engineering team can read PLC data and receive fault alerts, which shortens response time when a parameter drifts.
La personalización del control también incluye aspectos de seguridad y datos. Una cortina de luz o un bloqueo de puertas en la estación de sujeción, sensores digitales de posición para la seguridad de los moldes y control de espesor de pared de parafina en ciclo cerrado están todos integrados en el programa del PLC. Para los clientes que se someten a sistemas de calidad como ISO 9001 o los estándares de contacto con alimentos, la HMI puede registrar los contadores de ciclos, las temperaturas y el historial de fallos para respaldar la trazabilidad. La elección de personalización aquí es el idioma, el número de recetas guardadas y el nivel de funciones remotas y de datos que necesita su operación.
Motor and Drive Customization
Beyond voltage, the drive type is a customization decision. Hydraulic machines use a pump and valves for clamping and parison movement; servo-hydraulic machines add a servo-controlled pump that reduces idle energy; fully electric machines replace hydraulics entirely with servo motors. The right choice depends on your energy cost, your cleanliness requirement and your maintenance preference, and it is selected together with the voltage package. This is covered in more detail in the Totalmente eléctrica section below.
Function Module Customization
The function modules are the optional capabilities bolted onto the base extrude-and-blow cycle. They are selected per product and per market, and they are what separate a basic EBM machine from a purpose-built production cell. The most requested modules for Apollo machines are view stripe, programmable parison wall thickness control, automatic deflash, in-machine leak test and multi-layer co-extrusion.
View Stripe (View Line, Sight Strip)
A view stripe is a vertical band of contrasting or transparent material welded into the side of the container so the user can see the liquid level. It is produced by feeding a thin stream of colored or clear resin into the parison at a defined position while the main parison is extruded, then welding it during blowing. View stripes are common on detergent bottles, cosmetic bottles and pharmaceutical containers where the consumer reads the fill level. When you customize for a view stripe, Apollo adds a secondary material feed and a stripe die insert, and aligns it to the mold cavity so the stripe appears on the front face of the bottle.
Programmable Parison Wall Thickness Control
Parison wall thickness control, often built around a servo (Moog-type) mandrel, varies the die gap as the parison is extruded so the wall is thick where the part needs strength (base, handle) and thin where material can be saved (shoulder). This module directly cuts resin weight and improves drop performance. It is one of the highest-value customizations because it lowers material cost on every part for the life of the machine. Apollo programs the wall profile against the mold and container drawing during commissioning.
Desbarbado automático
In extrusion blow molding the parison leaves flash at the bottom weld and around the neck. Manual trimming is slow and inconsistent. Automatic deflash removes the flash inside the machine using synchronized cutting tools timed to the open cycle, delivering a finished part with no secondary trimming station. This module reduces labor, improves consistency and keeps the flash contained for regrind recycling. For high-output bottle lines it is effectively mandatory.
In-Machine Leak Test
An in-machine leak test pressurizes the finished container with air and checks for pressure decay, rejecting any part that cannot hold pressure. For chemical, pharmaceutical and food containers this replaces offline testing and catches pinholes before the bottle leaves the machine. Apollo integrates the test into the take-out or a downstream station and links the reject signal to the HMI so the operator sees defect rates in real time.
Multi-Layer Co-Extrusion
La coextrusión de múltiples capas utiliza una cabeza que combina dos o más flujos de fundido en un parison estructurado: por ejemplo, un núcleo reciclado o reciclado entre capas de piel virgen, o una capa barrera (resina de sujeción más resina de barrera) para envasado de hidrocarburos, como tambores químicos. Este módulo se especifica cuando el recipiente debe cumplir con normas de barrera o de contenido reciclado. Añade un segundo o tercer extruder y una cabeza de matriz con capas, y se combina con frecuencia con los armazones de uso intensivo ABLD para tambores y tanques.
Function Module Selection Table
| Function module | Función | Typical productos | Customization effect |
|---|---|---|---|
| View stripe | Welds a visible fill-level band into the wall | Detergent, cosmetic, pharma bottles | Adds secondary feed and stripe die |
| Parison wall control | Varies wall by position to save resin | All volume-sensitive parts | Añade el mandril de servo y el programa de perfil |
| Automatic deflash | Trims flash inside the machine | High-output bottle and can lines | Removes manual trimming, enables regrind |
| In-machine leak test | Air-pressure decay check, auto-reject | Chemical, pharma, food containers | Adds test station and reject logic |
| Multi-layer co-extrusion | Structures 2-3+ layers in the parison | Chemical drums, barrier packaging | Añade extrusoras y una cabeza de matriz en capas |
| Flash recycle / conveyor | Collects and regrinds flash inline | Any volume production | Adds granulator and conveying |
ABLD Heavy-Duty Series & Multi-Layer Customization
The ABLD series is Apollo’s heavy-duty EBM platform for containers from 20 liters to 1,500 liters: chemical drums, water tanks, liquid storage vessels, automotive fluid tanks and large industrial hollow articles. These parts are too large for continuous single-parison extrusion at speed, so the ABLD uses an accumulator die head that builds a measured shot of melt and then pushes it out as one large parison. The customization challenge at this scale is wall uniformity across a very large part and, for chemical drums, barrier performance.
For drums that carry aggressive contents, the multi-layer module is the key customization. A typical three-layer drum structure places a regrind or recycled core between two virgin high-density polyethylene skins, cutting material cost without sacrificing the clean inner surface. Where hydrocarbon permeation is regulated, a tie and barrier layer are added so the drum meets the transport standard while keeping the bulk of the wall in low-cost resin. Apollo configures the number of layers, the layer ratio and the second or third extruder size to the drum specification and the local regulation.
| Model (representative) | Screw diameter (mm) | Container range | Clamping force (kN) | Layers supported | Approx. installed power (kW) |
|---|---|---|---|---|---|
| ABLD 100 / 120 | 100 – 120 | 20 – 200 L | 300 – 600 | 1 – 3 | 90 – 150 |
| ABLD 150 | 150 | 100 – 500 L | 600 – 900 | 1 – 3 | 150 – 220 |
| ABLD 200 | 200 | 500 – 1500 L | 1000 – 1600 | 1 – 3 | 250 – 350 |
The ABLD frames are built around accumulator heads, so the customization discussion shifts from cavity count to accumulator shot size, head pressure and parison programming for a single very large part. The clamping force must hold the large mold closed against blow pressure, and the cooling time dominates the cycle. Apollo sizes the accumulator, the clamp and the cooling so the drum demolds cleanly without sag or weld-line weakness. For customers who also run smaller industrial parts, the same frame can be retooled with a different mold and a smaller accumulator shot, which is a form of customization that protects the investment as the product range changes.
Totalmente eléctrica Series for Clean & Eco Production
La serie completamente eléctrica ofrece capacidades que van desde 200 mililitros hasta 20 litros, como la ABLB, pero sustituye el sistema hidráulico por unidades servoeléctricas para la fijación, el movimiento del aparador y la presión. Esto elimina el aceite hidráulico de la máquina, lo que es importante para entornos farmacéuticos, en contacto con alimentos y de salas limpias, donde las nubes de aceite y las fugas son inaceptables. También reduce la energía en inactividad, ya que las unidades eléctricas solo consumen energía cuando se mueven, mientras que una bomba hidráulica funciona continuamente.
Customizing a Totalmente eléctrica machine follows the same mold and function logic as the ABLB, with the added decision of drive architecture. The benefits are consistent clamp force, precise repeatability and lower noise, which help in plants with strict energy or workplace rules. For a cosmetic jar or pharmaceutical bottle line where cleanliness and part consistency are the priority, the electric platform is the natural customization target even though the upfront tier is higher than a hydraulic equivalent. When you specify this series, Apollo confirms the servo brand, the clamp force class and the function modules, then validates the mold on the electric frame during factory testing.
The table below summarizes the three Apollo platforms so the customization choice between hydraulic, accumulator heavy-duty and fully electric is clear.
| Platform | Container range | Drive type | Best for | Multi-layer |
|---|---|---|---|---|
| ABLB | 0.2 – 20 L | Hydraulic / servo-hydraulic | Bottles, jars, jerry cans | Optional |
| ABLD | 20 – 1500 L | Accumulator, hydraulic | Drums, tanks, large parts | Yes, 1-3 layers |
| Totalmente eléctrica | 0.2 – 20 L | All-electric servo | Clean, food, pharma, eco | Optional |
Application Industries & End Products
Apollo EBM machines serve a wide spread of industries, and each industry drives a different customization recipe. The same ABLB frame customized with a cosmetic-jar mold, a gloss cavity and a leak test serves the personal-care market, while the same frame with a jerry-can mold, a view stripe and automatic deflash serves the lubricant market. Understanding the end product is how the customization is chosen.
- Food and beverage: water bottles, edible-oil bottles, sauce and condiment containers, dairy bottles. Typically HDPE or PP, often with leak test and food-contact grade resin.
- Daily chemical: detergent, shampoo, body wash and household cleaner bottles. Commonly specified with view stripe, automatic deflash and multi-cavity molds for high output.
- Industria química: agrichemical bottles, solvent jerry cans and 20 to 200 liter drums. Customized with barrier multi-layer structures and leak test for safe transport.
- Building material: adhesive and sealant pails, foam canisters and pipe-fitting drums. Often large ABLD parts with robust clamping.
- Medicina y farmacia: ointment jars, pill bottles and diagnostic containers. Favor the Totalmente eléctrica series for oil-free, clean production with tight leak-test and traceability.
- Automobile production: windshield-washer fluid tanks, coolant reservoirs and ducting. Large ABLD or engineered hollow parts, frequently with integrated features.
- Transportation: fuel and urea (AdBlue) tanks, hydraulic fluid containers. Barrier layers and strict leak testing are the norm.
- Cultural and sports: inflatable and hollow sporting goods, toy components and promotional items with custom shapes.
Because the customization is product-led, the fastest way to scope a machine is to start from the end product and work backward: define the container, the resin, the output and the quality rules, then let those inputs select the platform, the mold, the electrical package and the function modules.
OEM/ODM and How to Specify a Custom EBM Machine
Apollo ofrece personalización tanto para OEM como para ODM. En un acuerdo de OEM, el cliente proporciona el dibujo del producto o una muestra, y Apollo construye la máquina y el molde según esas especificaciones, a menudo con la propia marca del cliente en el HMI y en la etiqueta. En un acuerdo de ODM, Apollo también contribuye con el diseño del producto y el molde, basándose en su biblioteca de experiencias en el diseño de contenedores y moldes para proponer una forma y una solución de producción. Ambos métodos comienzan con la misma recepción de especificaciones.
The Specification Checklist
The table below is the intake Apollo uses to turn a product idea into a concrete machine proposal. Sending these inputs up front avoids the most common cause of delay: a proposal built around the wrong container assumptions.
| Input | What to provide | Example |
|---|---|---|
| Container drawing or sample | 2D drawing, 3D file or physical sample | 1 L round bottle, 28 mm neck |
| Volume range | Min and max fill volume | 0.9 – 1.0 L |
| Producción anual | Piezas por año o por turno | 6,000,000 bottles / year |
| Resin grade | Material and MFI | HDPE, MFI 0.3 – 0.5 |
| Local voltage and frequency | Grid standard | 415 V, 50 Hz |
| Function modules | Required capabilities | View stripe, deflash, leak test |
| Quality standards | Es necesaria la conformidad | Food contact, ISO 9001 |
Selection Recommendation Table
Once the inputs are known, the platform is selected. The table below maps common customer needs to a recommended Apollo configuration.
| Customer need | Recommended platform | Recommended modules |
|---|---|---|
| Small cosmetic jar, clean room | Totalmente eléctrica, 0.2 – 2 L | Leak test, gloss cavity |
| 1 – 5 L detergent bottle, high output | ABLB 65, 4 cavities | Ver línea, despegamiento, control de pared |
| 10 L lubricant jerry can | ABLB 75 / 90, 1 – 2 cavities | Wall control, deflash, leak test |
| 20 – 200 L chemical drum, barrier | ABLD 100 / 120 | Multi-layer, leak test, deflash |
| 500 – 1500 L water tank | ABLD 150 / 200 | Accumulator head, wall control |
| Pharma bottle, low energy | Totalmente eléctrica, 0.2 – 5 L | Leak test, traceability log |
La selección nunca es definitiva hasta que se prueba el molde en la máquina real. Apollo valida la cavidad, el programa de parison y los módulos de función en el taller, ejecuta la muestra a través de pruebas de fugas y de caída, cuando corresponde, y solo entonces confirma la hoja de especificaciones. Este paso de validación forma parte de la personalización, no es un paso adicional porque un molde que parece correcto en papel puede necesitar aún un ajuste de los perfiles de las paredes para funcionar correctamente.
Logica de personalización de materiales y multicapas
The resin decides much of the customization because each material has a different melt behavior, shrinkage and cooling need. Apollo machines process PE, PP, PVC, PA, PC, ABS, PS, EVA, TPU and PETG, and the screw, barrel and die-head temperatures are set per material. The table below maps common resins to the customization notes that follow.
| Material | Typical productos | Customization note |
|---|---|---|
| HDPE / LDPE | Bottles, drums, jerry cans | Standard; easy wall control, fast cooling |
| PP | Food, pharma, thin-wall | Lower melt temp, careful cooling to avoid sag |
| PVC | Clear bottles, medical | Thermal-sensitive; screw and temp profile tuned |
| PC/ABS/PS | Technical, display, tough parts | Higher melt temp, polished mold for gloss |
| PA / PETG / TPU | Engineering, barrier, flexible | Drying and layer design for barrier use |
| EVA | Flexible, squeezable | Softer parison; wall control critical |
Multi-layer customization is where material logic and function modules meet. A recycled-content drum uses a regrind core, which lowers cost but can carry odor or color; the virgin skin layers isolate the contents from that core. A barrier drum uses a thin tie-plus-barrier layer that may be only a small fraction of the wall, yet it decides whether the drum passes permeation rules. Apollo sizes each layer as a percentage of the total wall and sets the extruder for each layer so the structure is repeatable shot after shot. The customization decision is therefore the layer count, the layer ratio and the resins, all confirmed by testing the finished drum.
Installation, Commissioning & Service Soporte
A customized machine is only useful if it runs. Apollo’s service model, shared across the Wanplas group, covers the steps from factory acceptance to steady production. The mold and machine are tested together at the factory before shipment, so the customer receives a validated configuration rather than loose components. Engineers travel to site for installation and commissioning, set the parison program against the actual resin, and train the operators on recipe management and routine maintenance.
The Wanplas group backs every factory, including Apollo, with a USD 500 free parts allowance per year, a warranty that replaces damaged parts, a transportation guarantee and a production-capacity guarantee. Where quality falls short of the agreed standard, the Wanplas promise includes refund plus ten percent compensation. Remote monitoring lets the engineering team read PLC data and respond to faults without waiting for a site visit, which is especially valuable for customers in remote markets. Apollo also runs an open-factory policy: customers are welcome to visit the plant, watch their machine being built and approved, and audit the process before accepting delivery.
En el caso de líneas personalizadas, la puesta en servicio incluye un ensayo de producción con la resina y el molde propios del cliente, por lo que se demuestra el tiempo de ciclo documentado y la tasa de materia prima no se estima. Los componentes de los moldes de repuesto, los calentadores y las juntas se cotizan como un inventario recomendado, de modo que la línea no sea detenida debido a la falta de un componente necesario. La capacitación abarca el cambio de molde, el ajuste del programa de parison y los módulos de función seleccionados por el cliente, para que la planta pueda cambiar los productos y ajustar la línea sin ayuda externa para los trabajos de rutina.
Cost Tiers of Customization
Customization cost is best expressed as relative tiers rather than fixed numbers, because the final figure depends on mold complexity, cavity count, electrical standard and module count. The guidance below uses the Wanplas tier language of Low, Medium, High, Very High and Premium so you can budget the direction of the investment.
- Low tier: a standard ABLB frame with a single-cavity mold, local-voltage electrics and no function modules beyond basic deflash. Suitable for startups and low-volume custom shapes.
- Medium tier: ABLB with multi-cavity mold, view stripe and wall-thickness control. Typical for detergent and personal-care bottle lines where output and material saving matter.
- High tier: ABLB or Totalmente eléctrica with leak test, full function set and a polished cosmetic mold. Typical for food, pharma and branded packaging.
- Very High tier: ABLD accumulator machine for drums and tanks, often with multi-layer co-extrusion and leak test. Typical for chemical and industrial packaging.
- Premium tier: fully electric multi-cavity line with full automation, remote monitoring and traceability for regulated, high-value production.
La personalización de mayor valor suele ser el control del espesor de la pared de parison, ya que reduce el uso de resina en cada pieza durante la vida útil de la máquina, y la deflash automática, ya que elimina el trabajo repetitivo. El multicapa aumenta el costo, pero abre mercados a los que no pueden acceder los recipientes de una sola capa. El nivel adecuado es el que se ajusta a su volumen, el costo de la resina y las necesidades de cumplimiento, no el que tiene la lista de opciones más larga.
Frequently Asked Questions
What exactly is included when you customize an EBM machine?
Customizing an EBM machine covers three layers: the mold and cavity design that defines the container shape and output, the electrical configuration (voltage, frequency, PLC and HMI brand plus language), and the function modules such as view stripe, automatic deflash, in-machine leak test and multi-layer co-extrusion. Together they turn a base frame into a line built around your product.
Can Apollo build the mold for my specific bottle or jar shape?
Yes. Apollo designs and machines blow molds to customer drawings, samples or 3D files. The mold defines cavity number, neck finish, cooling channels and surface texture, and it is validated on the actual machine before shipment so the first production run matches the approved sample.
Which voltage and frequency should I specify for my country?
Specify the local grid: common standards are 380 to 415 V 50 Hz three-phase (Europe, Middle East, Africa, much of Asia), 220 to 240 V or 440 to 480 V 60 Hz three-phase (Americas), and 200 V 50 or 60 Hz (Japan). Apollo rewires motors, transformers and heaters to match the supplied standard so the machine runs without external conversion.
What PLC and HMI language options are available?
Mainstream PLC and HMI platforms are supported, with interface languages including English, Spanish, Arabic, French, Russian and others. Recipe management, remote monitoring and data acquisition are configured to match the operator’s workflow and any quality-system logging the plant requires.
What is a view stripe and when do I need it?
A view stripe, also called a view line or sight strip, is a colored or clear vertical band of contrasting material welded into the parison so the fill level is visible. It is common for detergent, cosmetic and pharmaceutical bottles where the consumer reads liquid level, and it is added as a secondary material feed with a stripe die insert.
How does automatic deflash improve an EBM line?
La deflash automática elimina el flash inferior y el cuello en el interior de la máquina mediante corte sincronizado, eliminando el ajuste manual. Mejora la consistencia de las piezas, reduce el trabajo manual y mantiene el flash contenido para el reciclaje mediante remoliendo, razón por la cual es prácticamente estándar en las líneas de producción de botellas de alta capacidad.
Can a custom EBM machine produce multi-layer barrier containers?
Yes. Multi-layer co-extrusion heads with two, three or more layers can be specified, typically a regrind or recycled core sandwiched between virgin skin layers, or a tie and barrier layer for hydrocarbon packaging such as chemical drums. Layer count, ratio and resin are confirmed by testing the finished container.
What information should I send to get a custom EBM quotation?
Send the container drawing or sample, target volume range, annual output, resin grade, local voltage and frequency, required function modules, and any quality standards. Apollo returns a tailored proposal with the mold, the machine model and a confirmed specification sheet after factory validation.
What is the typical lead time for a customized EBM machine?
Lead time depends on mold complexity, cavity count and module count, with the mold usually driving the schedule. Apollo confirms a realistic delivery window in the proposal and keeps the customer updated through factory testing, since the mold and machine are validated together before shipment.
Conclusion
Customizing an EBM machine is the discipline of matching three layers – the mold, the electrical package and the function modules – to one product family so the delivered line is ready to run on day one. Apollo, a Wanplas factory, builds this customization on proven platforms: the ABLB series for 200 milliliters to 20 liters, the ABLD series for 20 to 1,500 liters with multi-layer barrier options, and the Totalmente eléctrica series for clean, oil-free, energy-conscious production. The mold decides output and shape, the voltage and PLC package decides site compatibility, and the function modules – view stripe, parison wall control, automatic deflash, in-machine leak test and multi-layer co-extrusion – decide capability. By starting from the end product and working backward through the specification checklist, you turn a vague “I need a blow molder” into a concrete, validated machine proposal.
If you are scoping a new container or retooling an existing line, send your drawing or sample together with the volume range, resin, local grid and required modules. Apollo will return a tailored configuration on the right platform, validate the mold and machine together at the factory, and support installation, commissioning and ongoing production through the Wanplas service promise. You are also welcome to visit the plant, watch your machine being built and approved, and run a trial on your own resin before accepting delivery.
