When the client from Southeast Asia reached out with urgent requests for technical support on their extrusion blow molding machines used for jerrycan production, our engineering team didn’t hesitate. Jerrycans, those robust plastic containers essential for storing and transporting liquids in industries ranging from chemicals to agriculture, demand precise manufacturing—any flaw in the production process could compromise their durability and safety. What followed was a week-long journey that blended technical expertise, cross-cultural collaboration, and a shared commitment to excellence.
The mission began with thorough preparation. Our engineers pored over the client’s production data: the specific extrusion blow molding machines they operated, the type of high-density polyethylene (HDPE) resin they used, and the recurring issues plaguing their jerrycan output—uneven wall thickness, inconsistent neck finishes, and occasional leaks during pressure tests. Armed with this information, the team packed specialized tools, spare parts for critical components like die heads and blow pins, and detailed manuals translated into both English and the local language to ensure clear communication.
Upon arrival at the client’s location, the team was greeted by the production manager, whose urgency was palpable. “We’ve tried adjusting the air pressure and screw speed, but the jerrycans still fail quality checks,” he explained, leading them to the factory floor. The facility buzzed with activity, but the extrusion blow molding section stood out—two machines, each tasked with producing 50-liter jerrycans, sat idle for part of the day due to frequent rejections. Our engineers immediately got to work, starting with a comprehensive inspection.
First, they analyzed the parison formation, the critical step where molten HDPE is shaped into a hollow tube. Using a caliper, they measured the parison’s wall thickness at multiple points and noticed significant variations—thicker at the top, thinner near the bottom. This explained the leaks: the thinner sections couldn’t withstand the required pressure. “The die head’s mandrel isn’t aligned properly,” our lead engineer noted, adjusting the die ring to balance the material flow. Next, they checked the air injection system. The pressure gauge showed fluctuations, so they recalibrated the regulators to ensure a steady 12 bar during the blowing phase—a crucial setting for HDPE, which requires consistent pressure to expand evenly into the mold.
The mold itself was another focus. Jerrycans need precise threading on their necks to seal tightly, but the client’s molds showed signs of wear. Our engineers demonstrated how to polish the mold surfaces and adjust the clamping force to prevent flash (excess plastic) from forming on the edges. “It’s a combination of machine settings and mold maintenance,” one engineer explained to the client’s operators, who took notes diligently.
Beyond technical fixes, the team prioritized knowledge transfer. Over three days, they conducted hands-on training sessions: teaching operators how to troubleshoot parison defects, calibrate temperature zones in the extruder for different HDPE grades, and perform routine checks on the clamping unit. The client’s team, initially hesitant to deviate from their usual procedures, grew more confident as they saw immediate improvements—fewer rejected jerrycans, faster production cycles, and smoother finishes.
Cultural exchanges added warmth to the technical work. During lunch breaks, the client’s team shared local dishes, while our engineers talked about their experiences with blow molding in other countries. These interactions fostered trust, making the technical advice easier to embrace. “It’s not just about fixing the machine,” the production manager said on the last day. “It’s about understanding how to keep it running well long after you leave.”
By the time our engineers departed, the client’s production line was operating at 95% efficiency—up from 70% before their arrival. The jerrycans passed all pressure and drop tests, and the operators had a checklist of maintenance tasks to prevent future issues. More importantly, a partnership had formed. “We’ll send monthly production reports,” the production manager promised, “and reach out if we hit a snag.”
This journey underscored a simple truth: in manufacturing, technical expertise is vital, but so is the ability to collaborate across borders. For our team, seeing the client’s jerrycans roll off the line—strong, reliable, and ready to serve their purpose—was the ultimate reward. It’s a reminder that behind every machine, every plastic container, there are people working together to build something better. And in that collaboration, we find not just success, but lasting connections.
