2022 internal materials
Updated: Dec. 27, 2022
Originator: R&D Center▍ 2-Stage Type Biaxial Stretch Blow Molding Machine Line-up
Describes 8 series which are sold frequently in recent years.

Contents

Beverage

Dairy beverages
General foods
Seasonings, oils
Cosmetics
Pharmaceuticals
Daily goods

FRB1

FFB

FB

FR

FX

FGB

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FRB1

FFB

FB

FR

FX

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Industrial supplies

ContainerType
3 liters or less●

10 liters or more

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Wide mouth
container

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FYB

FMB

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FGB

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High
Heat-resistantcontainer
Heat resistancecontainer

FMB●

4 to 9 liters

Container withhandle

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FYB

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Copyright © 2022 Frontier, Inc.

1▍ 2-Stage Type Biaxial Stretch Blow Molding Machine Line-up

FFB

FB

4th generation general-purpose linear modelHigh performance 5th generation linear model

FR

FXJapan made Rotary model

FGB

Scalar robot adopted multi-functional model

FYB

Dedicated large container

Thick-walled bottle and Cosmetic containers
Copyright © 2022 Frontier, Inc.

2

2-stage 2-axis stretch blow molding machine

Toward an Easy-to-Use Blowing Machine

Stable high-quality and High-cycle molding

Since developing our blow molding machine, wehave been focusing on clean operation of pneumaticand electric drives. In recent years, we havestandardized energy-saving heater, blow-air recycle,
and other environmentally friendly systems.
Our line-up and technical capabilities, which are richin variations, will meet your demand.

Our machinery uses a 2-stage process and adapt the mostsuitable 2-axis blow molding method for PET resin andother resin. Preform and Bottles are molded separately, so
it is easy to adjust each to the optimum conditions. This isa molding method that can realize stable quality and highspeed production.

Technology Development Center

Comprehensive stretch blow molding engineering
Efforts

Initiatives
Improvementof existing products

Developmentof new products

Initiatives
Harnessingof new technology•

Fabrication of 3D modeling ••Prototype test•

CO2 reduction technology •Blowing of new materials•

Sample bottle for line-test•

Prototype with alternative •materials

To develop new technology

Weight reduction•

Molding efficiency

Towards blowing machines that can respond to your request!
If you have any problems, please feel free to contact us!

Copyright © 2022 Frontier, Inc.

3

▍ Molding test results
Formability... ◎: Mass production record/●: Prototype test experience, good blow performance/▲: Prototype test experience, no mass production
Abbreviated
name
PET
rPET

Fomal namePolyethylene terephthalate
Recycled PET resin

PurposeFeatureHeat
Formability Transparency resistanceChemicalresistance

Gas
Barrierproperty

ImpactresistanceBeverages, foodstuffs, cosmetics and
Ideal for 2 axis stretch blow molding
industrial parts

◎

〇

△

○

〇

〇

Beverages, foodstuffs, cosmetics

Repeated use of PET

◎

〇

△

〇

〇

〇

Bio PET

Bio PET resin

Beverages, foodstuffs, cosmetics

Attention is focused on reducing oil
consumption

◎

〇

△

〇

〇

〇

PET-G

Polyester with Glycol Additive resin

Cosmetics

Improved version of PET

◎

〇

○

○

○

○

PEN

PolyethylenN naphthalate

Cosmetics, industrial parts, pressurePET's top-ranked materials
resistant containers

◎

〇

〇

〇

〇

〇

PEF

Polyethylene flanoate

Beverages

Bio 100%

◎

△

△

△

〇

PP

Polypropylene

Pharmaceuticals, foodstuffs,
cosmetics, stationery goods

Crystalline general purpose resin,
floats in water

◎

△

〇

〇

△

〇

HDPE

High density polyethylene

Detergents, toiletries, medical
supplies, tablets

High chemical resistance

◎

△

〇

〇

△

〇

LDPE

Low density polyethylene

Pharmaceuticals

Softer than HDPE

●

△

△

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△

〇

BioPE

Bio polyethylene

Tablets, powders

Raw material is sugar cane

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△

〇

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△

〇

TritanCopolyester

Beverages, baby bottles

Washable with dishwasher

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〇

〇

〇

〇

ECOZEN

Bio-copolyester

Beverages, cosmetics

Bisphenol-A free

◎

〇

〇

〇

〇

〇

COP

Cyclic Olefin Polymer

Pharmaceuticals

Developed as a glass substitute

◎

〇

〇

〇

△

〇

COC

Cyclic Olefin Copolymer

Pharmaceuticals

Used in optical products and precisionlenses

●

〇

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△

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PA

Polyamide Nylon

Cosmetics

High toughness and excellent wear
resistance characteristics

◎

△

〇

〇

△

〇

PC

Polycarbonate

Gallon container

Excellent impact resistance

◎

〇

〇

△

△

〇

TPX

Polymethylpentene

Heat-resistant container

High transparency, high heat
resistance

●

〇

〇

〇

×

×

TPU

Thermoplastic Polyurethanes

Intermediate hardness between rubber
and plastic

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△

△

○

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PHBH

Biodegradable polymer

Ocean biodegradable

▲

△

×

×

×

×

Mapka

Plastic + Paper powder

Can be disposed of as paper

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×

〇

×

×

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PLA

Polylactic acid

Bio-resin●〇×

PLA+CMF

Polylactic acid + Cellulose microfiber

Expected to strengthen PLA

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×

△

×

×

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HEMIX

Hemicellulose-derived bio resin

Up-cycle resin

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×

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×

×

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ALTESTERPolyester

Tg is 30°C higher than PET

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LCP

Liquid crystal polymer

Rigid rod-like structure

▲

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Grilamid

Highly functional polyamide

Light and shock resistant

●

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Cellbrane

Cellulose acetate

Non-edible plant-based resin●△

Heimilan

Ionomer

Elongate well when heat is applied

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ASA

Acrylonitrile, styrene, and acrylic rubber

Better weather resistance than ASB

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HIPS

High-impact polystyrene

Impact-resistant UP with GPPS +rubber

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PMMA

Poly(methyl methacrylate)

Transparency over glass

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U-Polymer

Polyarylate

High transparency

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Beverages, cosmetics andpharmaceuticals

Vacuum pack

Lactic Acid Bacteria, Milk Drinks

×○

Copyright © 2022 Frontier, Inc.

4

Energy Conservation of Blow Machine I▍ Power consumption of our latest machineElectricity Consumption of FR Series

Electricity consumption per gram: 0.1～0.2W/g
Results

Full renewal of the heating zone••

Improvement of wavelength•

Air temperature control optimization•

High-efficiency heater box

40% reduction in preform heating
time.

•

Power consumption reduced by 30%
compared to our previous models.

Innovations in preform heating technology andhigher efficiency of the equipment have led to asignificant reduction in power consumption.

Energy Conservation Technology Ⅰ

Power reduction measures
Preform
4g weight
reduction

Latestmodel

Due to reduced
product weight

Comparison with
our previous
models-12%
Energy saving!

Lightweight preforms + latest model

4.37W

6

-29%
Energy saving!

4.95W

Energy-saving efficiency

4.37W

Power consumption-37%

Annual CO2 savings-41ton3.10W
Conventional
PF

Weightreduction PF

Previous
model

Latestmodel※ The above power consumption does not include the power consumptionof auxiliary equipment.

Back data
8,424BPH, 22 hours/day, 22 days/month and 12 months of operation
Production volume... 48,926K bottles,
Differences in power consumed per bottle... 1.85W
To reduce 90,513 KW of power consumed annually
CO2 emission factor Chubu Electric Power 0.462kg-CO2/kWhPrevious model: BIO-F4LIII, 4Cav, 3,780BPH, Net-power consumption 18.7kW
Latest models: FR-6M, 6Cav, 8,424BPH, Net-power consumption 26.1kW

Copyright © 2022 Frontier, Inc.

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3-Blow air recycling (previous model)

6-Blow air recycling (Latest model)
RecyclePressure

ExhaustPressure

Energy Conservation Technology Ⅱ

Reduced power consumption through improved air recycling rates

PX blowing

P2

P2

Time

P1
P1

P1 assist or
operation air
Time

P1

P2 Exhaust① Primary blow (P1)

④ Air recovery② Secondary blow (P2)② Px blowing (P2 assist)⑤ P1 assist or operation air③ Exhaust③ Secondary blow (P2)⑥ Exhaust① Primary blow (P1)

Air consumption is reduced by 35% by reusing of exhaust air!
Energy-saving synergistic effect by reducing compressor operating time！

Energy Conservation Technology Ⅲ

Power reduction measures
Low pressure air
Recycling
Difference between air
recycled and unused

Low pressure + highpressure air
Recycling

Difference between air
recycled and unused

-25%

-35%

Energy saving!

Energy saving!

360
m３/H

270
m３/H

Low

model

pressure air
recycling

Energy-saving efficiency
Electricity
consumption-150,000 kWh

Annual CO2 savings-72ton

360
270
m
m３３/H
/H

234
m３/H

Previous

Recycling low pressure air+ high pressure air

Previous
model

Low pressure+
High pressure
Air recycling

Back data
500ml 9,000BPH bottle-only power consumption.
Annual production hours: 258 days ×24H = 6,192H/year
Compressor Power Consumption Operating Rate 90%: 0.2kwh/m3
CO2 emission factor Chubu Electric Power 0.462kg-CO2/kWh※Figures are relative to those of us. Recycling efficiency varies with bottle volume and production number.

Copyright © 2022 Frontier, Inc.

6

Next-generation technology

RFID tag insert bottle

PAT.

Radio Frequency Identification

SATO Holdings Corporation

Partner company◼

An RFID tag was inserted into the neck of the bottle
Stack preform method• Neck piece... 3g• Preform...16g

Blow with an overlay of
preforms for the inner andouter layers.

Neck piece◼

RFID tag

Neck piece insert method
This is a structure in which theneck and body are divided.
Molding properties are notdifferent from those of singlelayer preforms.

RFID has reduced readability in the vicinity of liquid andor metals.
⇒ Solved by putting RFID tag in to the necks section!

Preform◼

Appeal to brand protection, realization of unmanned cash
registers, and inventory management.

◼

Bottles whose traceability has been established duringchemical management and/or export to overseas.

Patent No. 7182233◼

Facilities for producing RFID insert bottles are underintensive consideration.
1. RFID tag applicator
2. Neck peace assembler
3. Neck separation method

Patent No. 6857375

Introductory videos are from above.

NFC tag insert container
Near field communication◼

Next-generation technology
PAT.

Two-layer structure bottle technology
Inner layer by Stretch blow molding method
Outer layer by Cast molding method◼

Plant-derived thermosetting resin is used as an outerlayer material.

◼

Excellent heat resistance, designability and chemical
resistance.

◼

Soft touch and non-slip container.

◼

Built-in NFC tag at bottom of container.
➢ Prevents damaging and forgery of NFC tag◼

NFC can be read and written by smartphones. Therefore,

Inner layer
Outer layer
NFC tag
Patent No. 7082841

it is possible to appeal the needs of additional purchases
and regular purchases on the EC site.

Copyright © 2022 Frontier, Inc.

7

Paper Sleeve Bottle
Partner company

Reduction of resin usage andthin-wall bottle reinforcement technology

Oji Holdings Corporation• PET...16g• Paper-sleeve...10g◼

There is a limit to the weight reduction of bottles interms of strength. Therefore, we worked to develop
technology to reinforce the bottles with paper sleeves
to further reduce their weight.

◼

In-mold molding method is adopted, and the paper

sleeves and bottles are bonded together by heat during
blow molding.
◼

The material of paper sleeves pulp recycled from usedpaper such as newspapers and magazines. In addition,in consideration of paper recycling after use, it isprinted with ink that does not affect recycling.

◼

Paper and PET can be separated and recyclable afteruse.

Proposal of waste plastics reduce

Thin-walled flat bottle and recycling-oriented utilization methods
Partner company

Japan polyethylene Corporation and Oji Holdings Corporation◼

• LDPE...8g• Paper outer case...12g

Successful equalization of Thin-walled flat bottle wall
thickness by adopting double blow molding method.
The wall thickness of LDPE container is 0.2mm on
the long side and 0.1mm on the short side.

◼

This is a molding technology that enables thin-walled
flat containers for PET,HDPE,PP and TPX plastics.

◼

This is a technology to appeal to the demand for saleusing refill containers.

◼

Thin containers are available for mailing, so we willseek to reduce distribution costs.

Copyright © 2022 Frontier, Inc.

8

Bottle-to-Bottle proposal

Recycled PET below IV0.6 is reused as bottles.

◼

Bottled textile-and sheet-grade rPET◼

Developed a technology for recycling into bottles byadding a modifier to recycled material that has notbeen Solid-State Polymerized.
◼

Reduced energy and equipment costs if reusable
without solid-State Polymerization.

◼

Repeated regeneration of PET decreases the physicalproperties. Therefore, we aim to obtain a recycledmaterial suitable for blow molding by mixing
modifiers and restoring IV and physical properties.

Utilization of overseas recycled PET bottle◼

Since domestic r-PET in Japan has exceeded demand
for supplies and is rising in prices, the effective use of
low IV recycled PET materials made from overseas
was investigated.

◼

Implemented prototype blending with virgin PET andmodifying agents.

Barrier bottle

Proposal for Outer Layer Coated Bottle◼

Proposed high value-added container by alternativetechnique of Diamond-Like Carbon coating.

◼

Two-layer coating was applied to the outer layer
surface of PET bottles. Barrier performance tests
confirmed the effectiveness.
Primary layer

Secondary layer

BarrierProtection

Copyright © 2022 Frontier, Inc.

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Recycled PET

Supplement 1

Flow chart of PET recycle
Common1

Collection

2

Sorting3

Grinding

4

Cleaning

5

Flaking

ChemicalMechanical

New B-to-B

6

Depolyme
rization

6

Pelletizing

6

Pelletizing

7

Decolorizati
on Refining

7

Crystallization

7

PET resin

8Meltpolymerization

8

SolidState
Polymeriz
ation

8

Add modifier
mixingvirgin resin

9

SolidState
Polymerization9

PET resin

10

PET resin

Copyright © 2022 Frontier, Inc.

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Recycled PET

Supplement 2

What is Solid-State
Polymerization?
◼ The solid-state polymerization is a step of

CIF value for PET resin◼ Prices for imported CIF of virgin PET

performing heating and stirring while charging◼ Source: Trade Statistics, Ministry of Financenitrogen in a vacuum environment. It consists of five

◼ CIF:Cost Insurance and Freight, including

steps: crystallization, drying, heating (secondary
crystallization), polymerization, and cooling.
◼ By carrying out the solid-state polymerization,

freight charges (in JPY/Kg)

Year/month

CIF valuemolecules are polymerized with each other, and the2021/0186

strength (IV) of the resin is increased. Further, the2021/0291

2021/03972021/04111

2021/051202021/06122

2021/07122

2021/081202021/09124

2021/10126◼ Suitable IV for Film-processing is 0.65

2021/11131◼ Suitable IV for textile is 0.58

2021/121382022/01143

2022/021402022/03145

2022/04160

2022/05174

2022/06177

2022/07188

2022/081882022/09188

2022/10188

solid-state polymerization has an effect of reducing
impurities contained in the raw material resin.

What is IV◼ That is Intrinsic viscosity.

◼ IV value are reduced by heat.
◼ Suitable IV for 2 axis stretch blow molding is 0.80
◼ Suitable IV for sheet-forming is 0.72

IV

Typicalapplications

0.80

Bottle0.72

Sheet (egg pack, etc.)

0.65

Film

0.58

Long and short fibers

0.52

Short fiber

Copyright © 2022 Frontier, Inc.

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Hemicellulose Biomass PET◼

We learned that hemicellulose is abundantly containedin plant residues, which are discharged during theprocessing of foodstuffs made from barley (Beer etc.)
and soybeans (Tofu etc.), but most of them are disposedof. We thought that this hemicellulose could not beeffectively used, and we have developed a biomassbased PET resin by own formulation.
◼

Cellulosic resins are generally opaque, but this material
provides a highly transparent bottles. Also, blow-

Transparent bottles

moldability does not differ from common biomass-

From Beer residues

based PET.

Polylactic acid + Cellulose compound◼

This bottle is made from cellulosic material extracted
from old cotton clothing, and is made from a compoundof PLA.

◼

Initiatives to reclaim plants that should be disposed ofwith new value.

◼

The falling impact performance is improved bycompounding cellulose into PLA.

PET + TPX blending
Partner company

Mitsui Chemicals, Inc.
◼

The white masterbatch is generally blended withtitanium oxide.

◼

Study TPX blending as a substitute for titanium-oxide.
When PET and TPX are blended, they become cloudy
with light refraction and irregular reflection. This bottle

is light-resistant by taking advantage of this property.
◼

TPX is an organic substance, so it is easy to chemically
PET recycle.

Copyright © 2022 Frontier, Inc.

12

PET+TPX blending
Partner company

Results of light shielding test

Mitsui Chemicals Inc,

Test method◼ Cut out the test piece from the bottle, andmeasure the transmittance.
◼ Conducted at Nagano Prefectural Industrial
Technology Center.
Measuring
instrument

Ultraviolet-visible near-infrared
spectrophotometer

Manufacturer

Japan Spectroscopy Co., Ltd.

Model

V-670

Test purpose◼ The exposure of milk, beer and wine to sunlightand illumination produces an off-flavor called sun
odor.

Measurement results◼ Shading property is required as a measure against◼ Transmittance at 400nm wave length is compared.

sun odor. As measures in plastic bottles, whitemasterbatch (MB) blending is mentioned.

Please contact us for details◼ However, the titania contained in the white MB
was suspected to be brittle, we were looking for a◼ Though the light shielding property in thesubstitute for the white MB.

ultraviolet wavelength region is inferior to◼ We discovered that blending TPX into PET makes

the white MB, it is excellent in the otherwavelength region.

it pearl-tone white. It became a substitute for white
MB or measured the shading performance of TPX
blended products.

In-house measurement data
30

100

MB blending

PET alone

PET alone
75

Transmittance[%T]Transmittance[%T]20

MB blending

50

Please contact us for details

10

TPX blending

025

TPX blending
0

200

300

400

500

Wavelength[nm]

600

200

700

1200

1700

2200

Wavelength[nm]Wavelength [nm]Copyright © 2022 Frontier, Inc.

13

HDPE
Partner company

HDPE bottles without pinch-off
Japan polyethylene Corporation.
◼
◼

Made by 2 axis stretch single blow system
Compared to direct blow, the dimensional accuracy of
the threaded portion is high and trimming is not
required.

◼

Improved falling impact performance due to no pinchoff process in the stretch blow bottle.

◼

Mold flush less.

◼

Loss ca be reduced at the start of mass production.

◼

Bottle weight loss is possible compare with directblow method.

PET containers compatible with hypochlorite
Partner company Mitsubishi Gas Chemical Company, Inc.
◼

From the viewpoint of environmental friendliness, themovement to switch the bleach bottles from HDPE to
PET exists in the global market.

◼

MX nylon with excellent gas barrier and chemical
resistance →Compatible with hypochlorite as well◼

Mitsubishi Gas Chemical evaluated and verified thecontents and cracking resistance.

◼

Be mass-produced overseas.

Mitsubishi Gas Chemical HP
News release

51% paper content bottle
Partner company Mitsubishi Gas Chemical Company, Inc.
◼

This container can reduce calories at incinerationcompared to a 100% resin container◼

By adopting PP as a binder, it is excellent in heat
resistance performance. The container was filled with
98℃ liquid and allowed to cool naturally. The
deformation rate was 0.85%.

◼

Clear 10 drop tests from the height of 1.2m.

Copyright © 2022 Frontier, Inc.

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