An innovative PET blowing machine with the solutions unparalleled in the market

If the flexibility, durability and efficiency are most important to you, the new INSTAR 75 is the only solution you need.

The INSTAR 75 PET blowing machine is built according to the ZeroWaste philosophy.

We focus on ecology throughout low energy consumption and air recovery within the blowing process. To ensure the lowest carbon footprint we've developed two unique technologies: Worktech Advanced Heating System (WAHS) and Worktech Advanced Recuperation Process (WARP).

INSTAR 75 mark II main features

Fully automatic blowing process

From 2 to 8 cavities

WAHS™ – Worktech Advanced Heating System

WARP™ – Worktech Advanced Recuperation Process

Integrated compressors (optional)

Up to 50% energy consumption savings due to use warp and wahs

Max performance – 1 500 bottles per 1 cavity per hour

Easiest and quickest mould change in the market

Dispensing bottles for pneumatic conveyor (directly to the line)

No compressor room needed

Technical data

Technical data    
Max no of cavities and the performance depending on bottle diameter up to 55 mm – up to  8 cavities; 12 000 bottles/h  
  up to 63 mm – up to  7 cavities; 10 500 bottles/h  
  up to 75 mm – up to  6 cavities; 9 000 bottles/h  
  up to 90 mm – up to  5 cavities; 7 500 bottles/h  
  up to 115 mm – up to  4 cavities; 6 000 bottles/h  
  up to 155 mm – up to  3 cavities; 4 000 bottles/h  
  up to 230 mm – up to  2 cavities; 2 500 bottles/h  
 Supported screw types: BPF  
  PCO (all types)  
  38 Bericap  
  48 Bericap  
  oil screw  
  other types: on request  
Expected performance per 1 cavity 1250-1500 items per hour per cavity      
Work pressure up to 25 bar  
Transport of bottles machine is dispensing bottles to pneumatic conveyor   
Machine type „linear” type  
Stove: mechanical (pins guided on bearings - no friction)  
  single row. Horizontal "U" shape surrounding the IR radiators  
  screw upwards position of the preforms  
  preform threads shielded around their entire circumference and additionally cooled  
  mechanical system for preform overlay (star and actuator)  
  possible spacing between preforms: 38,1; 47,625; 57,15 mm  
  Infrared radiators: Near-infrared: NIR lamps lub Short Wave IR lamps (1 – 1.4 um)
    Numer of groups: 3 sets.
    Numer of sections in each group: 8
    Accuracy of section adjustment: 1%
    Total working length of the radiators: ~1500 mm
    The section cannot be adjusted horizontally (closer/farther to the preform)
Compensation system the compensation system for the closure of blow moulds implemented  
Mould change time up to 10 minutes (one preson required)  
Number of cavities change time up to 30 minutes (two persons required)  
Screw type change time up to 240 minutes (two persons required)  
Power installed: stove - 55 kW.  
  machine - 10 kW  
  compressors - 50 kW  
Cooling of compressors, moulds, stove and servo motors liquid (closed system with air blow for mould change)     
Cooling power demand ~25 kW.  
Chilled water demand ~20 litres per minute  
Dimensions [L x W x H] 7500 x 2000 x 4000 mm (integrated compressors option)  
Weight ~4500 kg.  
Control system Beckhoff - C6920  
Servo drives Hiwin and Beckhoff linear drives  
Pneumatics Festo  


The orientator construction is a proven classic housing based on rotating rollers ensuring trouble-free orientation of preforms. Moreover the orientator is equipped with fast adjustment system.

Just a few turns with one crank is enough to change the spacing of the rollers. The counter mounted on the crank allows the quick and precise return to previous settings.

The rotation of the rollers and the vane grinding the preforms, can be quickly and easily adjusted within the touch control panel.


The use of an innovative and compact stove design. Thanks to proprietary solutions, the stove has the following features:

Preform collection
The preforms are collected by a star that assures smooth application on pins, even at high speed – up to 12 000 items per hour.

Preform type change
In case of preform type change, the star and the chain with pins can be easily replaced thanks to the smart stove design.

Another important issue is adjustable spacing of the furnace pins that can be adapted to different diameter of the preform. Regardless of whether a 14g or 85g preform is used the space between the preforms is small, so the heating efficiency is very high regardless of the type of preform used.

Damping system
To ensure the longer life of heating system the stove is suspended on a special shock absorbing system that reduces the transmission of vibrations from the machine to infrared radiators.

Pneumatic system for preform removal
The elimination of mechanical parts within the take-off process, the system will work for a long time without failure. Another advantage of this solution is easy adaptation the preform removal system to different numbers of cavities.

Modular heating system
Modular structure of the lamp system allows the machine operator to easily install and remove them. That makes lamp servicing much simpler as well.

Precise lamp power adjustment
The stove consists of three independent lamp modules, each of them has eight sections. As the effect we have 24 power levels to be set by the operator.

Piec - sekcja lamp

Podawanie preform do pieca 1

Podawanie preform do pieca 2


Thanks to the smart design, it is very easy to adapt the system to different types of preforms as well as various number of cavities in the mould.

Simultaneous implementation of both processes saves time and simplifies the construction of the system.


Parallel implementation of both processes saves time and simplifies the design of the machine. Simultaneous and synchronized movement of all moving parts of the blow moulding module (moulds, bottom, heads) assures time saving and construction simplification

The blow module is driven by the linear motor. Thanks to this, electric energy is converted into reciprocating motion without any mechanical elements such as gears, connecting rods, toothed bars.

Thanks to the Quick Mould Replacement System, it takes just a few minutes to replace the moulds.

Blow heads fast mounting system allows the machine to be adapted quickly to a different number of cavities. The time needed for the change does not exceed a few minutes.

Moving parts sinusoidal travel is continuous and smooth (except for the blow process) so there is less wear on the parts (without knocks and large overloads).

There are two important systems introduced to the blowmolding module: the mould pressure system and the slack compensation unit. It ensures tight adhesion of both halves of the mould to each other, thanks to which the seam on the bottle is smaller and less visible.

MES analysis of the module

Kinematic scheme of the blow module

Possible bottle size and capacity you can get of the INSTAR 75 Mark II blowing machine


The stretch rods are driven by a linear motor and no mechanical are used thus the electricity, without additional losses can be converted into reciprocating motion.

The implementation of servo drive gives us full and easy control over the rods. Their movement is precisely synchronized with the whole cycle and other components movement. The settings like depth or stretching speed can be changed from the operator's touch panel.

INSTAR 75 offers the possibility of changing the number of active cavities. Number of cavities has to match the number of stretch rods, thus both cavities and rods must be changed at the same time. The magnetic bar fastening system allows the operator to perform the adaptation in a quick and easy way.


Most PET bottle conveyors use a fan and an air duct. In INSTAR 75 Mark II the conveyor uses high pressure air and the Venturi tube effect. The transporting module does not have to be closed and it can be much smaller than a conventional pneumatic conveyor.

The conveyor is more aseptic and easier to clean and in addition, the bottle transport is much faster and more ergonomic.

Bottles dispensing by the pneumatic conveyor allows easy integration of the machine with the bottling line.


Our proprietary solution of ultra-fast pneumatic valves allows multiple switching on and off the valves during the blowing process.

This allows INSTAR 75 to recover most of the air used within the bottle blowing process, up to 75% of the air can be recovered.

When the efficiency of the compressors is taken into account, about 50% of the electricity needed to power the compressors can be saved.

The integration of the compressors into the machine allowed us to create an almost closed air system (only 10% of the air used in the process is taken from outside).

This leads to 10 times longer filter life, and very important issue – there is 10 times less humidity to be removed from the air system.

In addition, the energy efficiency of the system is also increased and the infrastructure costs related to the construction of the compressor room and air supply system are significantly reduced.

The use of water as the coolant for compressors, and all other components of the machine, makes it possible to easily dissipate thermal energy from the machine and use it, for example, in central heating installations. The use of water also results in much quieter machine operation.

Using a main screw compressor and the auxiliary screw booster causes that the system will run for a long time and without any maintenance needed..


The control system is based on professional components from Beckhoff.

The machine works under the control of IPC (Industrial Personal Computer) with very high computing power and speed when compared to PLC.

IO modules (I / O), servo drives and other components communicate using very fast and open EtherCat network (devices scan period is shorter than 1ms).

All the control and settings are available from the large, colorful, touch control panel, the service and control can also be done remotely over the Internet.

In addition, INSTAR 75 Mk II collects statistical data on process allowing to predict problems or failures resulting from wear and tear.).