Vacuum Flask Shell Line & Hydroforming Guide

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Vacuum Flask Shell Line & Hydroforming Guide

Planning a thermos shell plant starts with one question: do you need a partner for the whole line, or a single forming cell? A vacuum flask line supplier maps every station from blanking to packing, while a water bulging machine manufacturer owns the hydroforming step that actually shapes the shell. This guide covers both, anchored on the JS98 water bulging machine (Item No. 00100 by JACKSON): how the line flows, what each specification row means for your part, and how to size the forming cell before you quote.

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Path A — Plan a complete vacuum flask shell line

You are building or expanding a thermos shell plant and need the station sequence to line up.
You want one scope covering blanking, tube making, cutting, forming, finishing and packing.
You need footprint, utilities and staffing agreed before equipment is ordered.

Path B — Specify or replace a water bulging machine

You already run a metalware line and the forming cell is the constraint.
You need to match opening height, table area, pressure and beam speed to a real part.
You are comparing the 98 series against the faster 98S series.

Model bands in the range

JS98-150T JS98-200T JS98-250T JS98-300T JS98S-150T JS98S-200T JS98S-250T JS98S-300T

03 · Machine anatomy

Water bulging machine: how the forming cell works

The machine implements the fluid pressure forming process: high-pressure liquid pushes a hollow part or tube blank outward until it gradually fits the mould cavity, producing parts of a specified shape and size. Item No. 00100, JACKSON.

Water bulging machine structure with worktable, main cylinder and hydraulic system

Load path: tube blank in through the worktable, axial feed from the main cylinder, air out the top, part out on the sliding table.

Worktable — liquid injection pointLiquid is injected into the vertical tube blank through the worktable, so table size and flatness decide how the blank seats under pressure.
Upper side — excess air removalExcess air is removed from the upper side of the blank, keeping the forming chamber liquid-filled rather than air-pocketed.
Main cylinder — axial feedingAxial feeding is completed by the main cylinder, which pushes material into the expanding zone as the part forms.
Movable sliding tableLoading and unloading happen on the sliding table, which also lowers machine height and improves stability and reliability.
Two-way cartridge valve hydraulicsThe hydraulic system is controlled by a two-way cartridge valve with low pressure loss and stable, reliable action.
Auto lubrication systemAutomatic lubrication reduces manual service stops between production runs.
Material return and replenishmentThe return function increases the bulging limit and is especially useful on complex water swelling types.
Formation control by waterForming is controlled by the water circuit, and the supercharger's large flow rate fills the blank rapidly — fast forming speed and high forming efficiency.

Simple structure, large opening heightThe frame allows forming of parts with large axis length.
High working pressure, clear forming textureHigher pressure produces a cleaner surface pattern on the formed shell.
Fast, efficient, low energy consumptionThe process replaces traditional rubber bulging and can form parts with complex surface shapes.

Main technical parameters — JS98 series

Values as published for the 98 series across the four model sizes. Confirm the final configuration against your part drawing before ordering.

Parameter	JS98-150T	JS98-200T	JS98-250T	JS98-300T
Master cylinder nominal pressure (kN)	750	1000	1250	1500
Master cylinder process (mm)	800	800	800	800
Nominal pressure of booster cylinder (kN)	750	1000	1250	1500
Booster cylinder stroke (mm)	400	400	400	400
Water cylinder capacity (L)	4	4	4	4
Water tank capacity (L)	80	80	80	80
Oil tank capacity (L)	1000	1000	1000	1000
Maximum pressure tank (MPa)	100	80	80	85
Maximum opening degree (mm)	1600	1600	1600	1600
Effective area of the working table (mm)	550×500	580×550	650×650	700×700
Slide area (mm)	500×380	520×400	600×550	650×550
Slide travel (mm)	200	250	250	350
Motor power, 98 series (kW)	11+3	18.5+5.5	22+5.5	30+7.5
Size (m)	2×1.7×3.9	2.1×1.7×4.1	2.3×1.9×4.2	2.4×1.9×4.3

Sliding beam speed and motor power — 98 vs 98S series

The 98S series runs the same forming principle with higher beam speeds and higher motor power. Use this table when cycle time, not part size, is your constraint.

Parameter	150T	200T	250T	300T
98 series — rapid descending (mm/s)	350	300	200	360
98 series — mold (mm/s)	50	25	27	30
98 series — quick return (mm/s)	320	250	230	300
98S series — rapid descending (mm/s)	437	375	250	450
98S series — mold (mm/s)	62	31	34	37
98S series — quick return (mm/s)	400	312	287	375
98S series — motor power (kW)	14+3	23*5.5	27+5.5	37+7.5

04 · Material & part fit

Which materials and parts suit water bulging

The process is designed to handle stainless steel, copper, aluminum and iron, and it replaces traditional rubber bulging. Below is what each listed material means for the buyer, followed by the part families named in the machine's application range.

Hydroformed metal parts and tube blanks formed on a water bulging machine

Materials listed for the process

Material	Advantage that matters to you	Confirm before quoting
Stainless steel	Also covered in the site's hydroforming notes on stainless steel tubes and vacuum flask shells — the core shell material.	Tube blank diameter, wall thickness and the pressure needed for the expansion.
Copper	Formable to complex surface shapes without rubber-bulging tooling.	Blank condition, lubrication and mould surface preparation.
Aluminum	Light metal parts formed under the same water-pressure principle.	Pressure setting against wall thickness to avoid over-expansion.
Iron	Listed material for hollow parts and pipe-type components.	Corrosion protection and downstream finishing plan.

Materials named on the machine page: stainless steel, copper, aluminum and iron.

Part families named in the application range

Drinkware shells

Vacuum cups and thermos bottles are the classic case: a long, closed hollow body formed outward against a mould. Check maximum opening degree and table area first.

Kitchen and table items

Kettles, tableware and utensils rely on complex surface shapes. Check the pressure tank rating and the mould design for the shape change.

Tube and fitting products

Stair handrails and decorative pipe fittings are long pipe-type parts. Check axial feeding and the material return function for deeper bulging.

05 · Scenario → specification

Match your part to the right specification row

Start from the part you need to produce, then read the row that actually decides the model. This keeps the model choice tied to your product instead of to a brochure ranking.

If your project looks like this	Check this specification	Why it decides the model
Long, slim shell with a large axis length	Maximum opening degree — 1600 mm	The page states the large opening height allows forming of parts with large axis length.
Wide part or large mould footprint	Effective working table area — 550×500 / 580×550 / 650×650 / 700×700 mm	The table and slide must clear your mould and blank before pressure is applied.
Tight cycle time per shell	Sliding beam speeds — rapid descending 350–437 mm/s, mold 25–62 mm/s, quick return 230–400 mm/s	The 98S series runs higher beam speeds than the 98 series, which shortens non-forming time.
Hard material, thick wall or deep expansion	Maximum pressure tank — 100 / 80 / 80 / 85 MPa, plus material return and replenishment	The page states the return function increases the bulging limit and suits complex water swelling types.
Frequent mould changes or heavy parts	Movable sliding table and slide travel — 200 / 250 / 250 / 350 mm	The sliding table supports loading and unloading and improves machine stability and reliability.
Limited installed power on site	Motor power — 98 series 11+3 kW to 30+7.5 kW; 98S series 14+3 kW to 37+7.5 kW	Electrical supply follows the model and series you select, not the other way round.
High daily output of short parts	Supercharger flow with water cylinder 4 L and water tank 80 L	The page states the large supercharger flow makes liquid filling rapid, so forming speed is fast and efficiency high.

06 · Line configuration

Three line builds: cell, core line and turnkey

The scope you choose decides how much of the station sequence you own. Water-bulging figures below are the published values for the JS98 range; figures for surrounding stations are fixed at layout-drawing stage, when your floor plan is known.

Decision	Single forming cell	Core shell line	Full turnkey line
Water bulging scope	One JS98 or JS98S machine, 150T to 300T, with the mould set for your part family.	One forming cell matched to shell size; model band confirmed against part length, table area and pressure.	Forming capacity planned together with spinning/necking and finishing so the cell is not the bottleneck.
Stations included	Hydroforming only — blanks arrive ready to form.	Blanking, pipe making and cutting, water bulging, spinning/necking, finishing, assembly.	Blank cutting through to assembly and packing, sequenced as one production flow.
Equipment footprint	Machine size 2×1.7×3.9 m (150T) to 2.4×1.9×4.3 m (300T), plus sliding table travel and mould handling clearance.	Footprint of the forming cell plus upstream and downstream stations, fixed during layout planning.	Whole-line layout drawing produced from your building dimensions before shipment.
Utilities to confirm	Electrical supply for the selected motor power; water feed for the 80 L tank; hydraulic oil for the 1000 L tank.	Cell utilities plus the demand of the other stations, agreed station by station.	Whole-plant utilities schedule including power, water and any service air for neighbouring stations.
Staffing focus	Operator at the movable sliding table loading blanks and removing formed parts.	Cell operator plus station operators along the core sequence.	Headcount follows the number of stations in scope — planned with you rather than assumed.
Mould planning	Customizable moulds built to each product specification; storage near the cell.	Mould set covering the shell family you plan to sell, with slide travel 200–350 mm.	Mould programme covering the full range across forming and necking stations.

07 · Factory readiness

Check these eight points before the machine ships

Most installation delays come from building and utility items rather than the machine itself. Run this list during the enquiry stage.

Ceiling height and opening clearance Machine height runs from 3.9 m to 4.3 m depending on model, and the maximum opening degree is 1600 mm. Leave room for loading the blank vertically.

Floor area and machine base Plan the footprint at 2×1.7 m up to 2.4×1.9 m, then add clearance for the sliding table travel and mould movement.

Water supply Forming is controlled by water — the cell carries an 80 L water tank and a 4 L water cylinder. Confirm a clean supply point close to the machine.

Hydraulic oil handling The oil tank is 1000 L. Plan the first fill, storage and eventual disposal before commissioning day.

Electrical supply Motor power ranges from 11+3 kW to 30+7.5 kW on the 98 series and from 14+3 kW to 37+7.5 kW on the 98S series.

Mould storage and handling Moulds are customizable per product, so plan racking and a lifting route beside the forming cell.

Blank staging and part removal Blanks enter vertically through the worktable and formed parts leave on the movable sliding table — keep both sides clear.

Service access Leave access to the two-way cartridge valve hydraulic system and the auto lubrication points for routine checks.

08 · Project brief & quote

How to move from brief to quotation

Send the four inputs below and the model, mould and line scope can be matched to your product. The clearer the part drawing, the faster the quotation is useful.

Step 01

Send the brief

Part type, material, blank dimensions and the shell family you intend to produce, plus whether you are planning a full line or replacing one forming cell.

Step 02

Confirm the model band

Opening degree, working table area, maximum pressure tank and motor power are checked against your part to pick the 98 or 98S model size.

Step 03

Agree mould and process details

Customizable moulds are built so each product meets exact specifications — confirm the mould plan, water supply and the material return setting.

Step 04

Confirm commercial scope

Finalize machine scope, shipping, installation and training arrangements, and any OEM or ODM project requirements, before the order is placed.

Send your shell line or forming cell brief

Tell us the part, the material and the output you are planning. We will match the JS98 or JS98S model to your part dimensions, confirm the tooling plan, and quote the equipment scope — including OEM and ODM projects with customizable moulds.

Review Machine Specifications

Frequently Asked Questions

what is a water bulging machine used for?

it implements the fluid pressure forming process: high-pressure liquid forms hollow parts or tube blanks outward until they gradually fit the mould cavity and take the specified shape and size. it is mainly suitable for hydroforming pipe parts.

which models are available?

the range lists js98-150t, js98-200t, js98-250t and js98-300t, plus the js98s-150t, js98s-200t, js98s-250t and js98s-300t variants. item no. 00100, brand jackson.

how do i choose between the 98 and 98s series?

compare sliding beam speeds. on the 150t size, rapid descending is 350 mm/s on the 98 series against 437 mm/s on the 98s series, and mold speed is 50 mm/s against 62 mm/s. the 98s series also runs higher motor power, from 14+3 kw to 37+7.5 kw.

what materials can it form?

the machine is designed for stainless steel, copper, aluminum and iron. it replaces traditional rubber bulging and can form parts with complex surface shapes.

how much shop utility does it need?

the water cylinder holds 4 l and the water tank 80 l, the oil tank holds 1000 l, and motor power runs from 11+3 kw to 30+7.5 kw on the 98 series. machine size ranges from 2×1.7×3.9 m to 2.4×1.9×4.3 m. confirm the final supply requirements for your selected model with the engineering team.

can the moulds be customized?

yes. customizable moulds ensure that each product meets exact specifications, so the forming cavity is built around your part rather than the other way round. share your part drawing with the enquiry.