PET Containers and Blowing
Blowing and filling shop: layout, floor area, utilities
Layout errors cost more than equipment selection mistakes: a line can be tuned, but a load-bearing wall and ceiling height cannot. Layout is calculated before machines are ordered.
Flow logic
A proper shop is built on the principle of one-directional flow: raw material and preforms enter from one side, finished pallets exit from the other, and clean and dirty zones do not cross.
Blowing is separated from filling: it is a noisy, dusty, hot section. Between them, an air conveyor transports the bottle or a combiblock is used where blowing and filling are combined in one frame.
A combiblock saves floor area, removes the conveyor and reduces the risk of bottle contamination between blowing and filling, but it ties blowing and filling together: a stop of one unit stops the other.
Area and utility guidelines
| Parameter | 6,000 bph line | 12,000 bph line |
|---|---|---|
| Production hall area | 600-900 m² | 1,200-1,800 m² |
| Height to underside of structures | from 5 m | from 6 m |
| Preform and cap warehouse | 200-300 m² | 400-600 m² |
| Finished goods warehouse | from 500 m² | from 1,000 m² |
| Electrical power | 250-400 kW | 500-800 kW |
| Floor | Industrial slab with slopes and drains | Same, with higher load capacity |
What is included in the building project
- Slopes and drains
- Filling is a wet process. Without proper slopes water stands on the floor, creating risks for personnel and microbiology.
- Ventilation
- Separate for blowing with its heat and for the filling zone with its air cleanliness requirements.
- Maintenance zones
- Minimum 1.2 m walkways around machines and space to roll out units for service.
- Gates and forklift routes
- Forklift paths must not cross the filling zone.
- Expansion reserve
- Space for a second line or additional format is included from the start.
FAQ
Blowing in a separate room or in a common hall?
A separate room is preferable because of noise, heat and dust. With a combiblock the question is resolved because blowing is integrated into the filling block.
What ceiling height is needed?
From 5 meters for a standard line: this is required by the air conveyor, palletizer and service of upper machine units.
Can production be placed in a ready-made hangar?
Often yes, but it requires an industrial floor, utility networks and meeting the cleanliness requirements of the filling zone. This is a separate budget item that must be calculated before leasing.
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