New syntactic material assists in creating thermoform molds

May 15th, 2012

THERMOFORMING trelleborg New syntactic material assists in creating thermoform molds

Trelleborg Offshore, a global engineering group with leading positions based on advanced polymer technology and in-depth applications, is launching a high-performance Syntac T-max syntactic material that will allow for better mold control in the thermoforming process of creating blister packs.

The material is made of a Teflon-impregnated syntactic foam with a composite plug-assist material that is used for processes that require high-temperature material with superior slip and release properties.

Currently, Trelleborg Offshore produces material at sites in Mansfield, Mass., and Skelmeresdale, England.

Jim Payton, sales manager, said Syntac T-max brings consumers another first-class solution to meet their changing needs of Trelleborg Offshore. The new Syntac T-max boasts good abrasion-resistant properties and can run to a maximum temperature of 450° F. The material was designed for both uses on sheet-fed and heavy-gauge thermoforming.

Also presented at NPE2012, was Trelleborg Offshore’s tough Eccolite Ultra syntactic composite material which has a formulation that conducts ductility with low thermal expansion at temperatures up to 392° F.

The Eccolite Ultra has the toughness to meet strict standards for thermoforming plastic materials and is within U.S. Food and Drug Administration regulations for its use in food packaging said Will Ricci, sales manager for Trelleborg Offshore, said

Eccolite Ultra also allows machinists to run complex details to high cycles that create chill or swirl marks or break plugs. Shop dust is also kept to a minimum because when machined, the materials ribbons or chips when being machined.

For more information, visit : Plastics News

Source: Plastics News

Multivac to present innovative thermoforming machine

May 9th, 2012

THERMOFORMING multivac 300x55 Multivac to present innovative thermoforming machine

Multivac, a packaging specialist company from southern Germany, announced that they will be presenting an innovative packaging solution for sensitive pharmaceutical and biotech products at ACHEMA (June 18 – 22, 2012) in Frankfurt. The innovation is based on a thermoforming packaging machine that includes a completely new machine concept. This new machine has been designed with the idea that some applications require a high degree of flexibility for packaging challenging products.

The new machine is designed specifically for quick and secure line clearance. The current system that Multivac’s system runs on meet the requirements of frequent, reproducible, and rapid format changes. The new machinery has been extended to the complete cutting tools, which are generally used in pharmaceutical applications for single-piece cutting of sealed packs. What this means is that Multivac can now achieve a high level of packaging flexibility with all different kinds of batch sizes.

Other tasks that Multivac offers is a wide range of handling modules such as loading finished packs into outer cartons by removing the packs out of the cutting tool. Rejected packs will be automatically separated out and placed into a container.

The user-friendly line-motion control that includes a HMI 2.0 operator as well as sensitive sensor technology in the machines ensure that a high-quality product is consistently being produced and maintained.

For more information: Multivac

Pigment Free Plastics Sought by Hospitals

April 27th, 2012

THERMOFORMING pigment Pigment Free Plastics Sought by Hospitals

The nation’s largest privately held manufacturer and distributor of healthcare products, Medline, is expanding its plastics product processing in order to meet the demand for green products.

Medline is responding to the nearly 8 percent of customers who are now buying the pigment-free products that the company manufactures. In the product line for the natural site includes bedpans, wash basins, soap dishes, pitchers, carafes, and trays.

“Our pigment-free products support greener manufacturing because they eliminate the need for potentially harmful chemicals during the manufacturing process,” Francesca Olivier, Medline sustainability program manager, told Plastics Today.”

The packaging for these products use 35% post-consumer tree pulp and are engineered to ship more efficiently which results in a reduced carbon footprint.

“There is definitely a trend toward green purchasing in hospitals,” said Olivier. “Leaders in the health care industry are reaching beyond the boundaries of their hospital doors and raising standards upstream in their supply chain…As a manufacturer and distributor, we have improved our own manufacturing and product design to respond to such demands.”

Consumer Goal: Chemical Reduction

One primary customer, Dignity Health (San Francisco), for example, has a chemical reduction policy.

“We are proud that Dignity Health is the first health system that is changing its plastics to dye-free products for our patients across our network. It helps protect and improve the environment and, ultimately, public health,” said Sr. Mary Ellen Leciejewski, Dignity Health Ecology Program Coordinator. “Our support for environmentally responsible products underscores Dignity Health’s long-standing commitment to sustainability.”

By making the switch to pigment-free plastics, Dignity Health will divert an estimated 2,935 pounds of pigment from leaking into the soil and groundwater. The total value of their contract with Medline is $1 million per year.

When asked how Medline certifies when a certain type of product is more environmentally beneficial than another, Olivier told Plastics Today: “In the research done into each of our green products, we review six areas of the product’s life: raw materials, manufacturing, packaging, transportation, product use, end of life/disposal. Not only does this rigorous process ensure that no greenwashing occurs in our environmental claims, but it raises the standards of what we expect from our own suppliers and their impact on the environment.”

Another issue that has arisen for Medline is addressing a full line of  reusable autoclavable plastic items.

“Health care is second only to the food industry in terms of waste generation – the most commonly cited statistic is 6,600 tons of waste is generated every day by the health care industry,” said Olivier. “Hospitals are realizing that they can reduce the amount of waste that leaves their facility by changing the products that they bring into it. We see this in the trend toward reusable products, as well as products that can be recycled or are part of a “take-back” program. By making strategic purchasing decisions like these they can not only improve their impact on the environment, but become more efficient and save money.”

As an industry leader, Medline manufactures more than 125,000 products to hospitals, extended care facilities, surgery centers, physician offices and home care dealers in the nation. The company has quickly become the fastest-growing distributor of medical and surgical suppliers in the U.S. in the last five years, and has served as the primary distributor to more than 450 major hospitals and healthcare systems.

Medline operates injection molding, blow molding, and extrusion machinery.

Source: Plastics Today

 

What you Need to Know about Blister Packaging

April 19th, 2012

THERMOFORMING blister packaging 300x300 What you Need to Know about Blister PackagingBlister packaging. The term blister packaging may not be familiar with many general consumers, and should probably be referred to as frustration packaging. Blister packaging is the see-through packaging that encases the product and seems almost impossible to open, even with the assistance of scissors or even a knife.

Although many consumers have been frustrated with the lack of easy access to their product that comes with blister packaging, many manufacturers have come to love it for the benefits is provides.

1. High Visibility: Blister packaging is clear, so it allows the product to be highly visible which in turn can produce more point of purchase sales, reducing packaging costs

2. Reduces Shoplifting:  Because the packaging is seemingly impossible to open, it would be hard for shoplifters (who often seek out consumer electronics) to open the packaging and steal the product. This is good for both retailers and manufacturers.

So what exactly is blister packaging?

Blister pack is a term for different types of packaging that is pre-formed to be used for small consumer pharmaceuticals, foods, and goods. A blister pack is typically describes as a cavity or pocket that is made out of a usually thermoformed plastic that has the backing of paperboard or plastic. A blister that folds onto itself is often called a clamshell.

Once the product is encases into the cavity, it is sealed shut by a heating process. Blister packs can come in all different sizes and can be very small or very large. Manufacturers know that there are many different forms of blister packaging but in general, they all function the same with many different possibilities. .

Now, enjoy a video of Larry David on Modern Family vs. Bad Packaging

UK Scientists Research Eggshell Recycling

April 13th, 2012

eggs 300x230 UK Scientists Research Eggshell Recycling

Although the Easter season has come and gone, The Food and Drink iNet is hatching plans (no pun intended) to research the extract materials from egg shells to find useful ways to recycle them after they have been used.

The study is part of a research project by The Food and Drink iNet, which is based at Southglad Food Park, Nottingham, UK, along with a group of advisers from across the UK and including Nottingham Trent University, the University of Lincoln, and the University of Nottingham.

University of Leicester scientists in the Department of Chemistry that specialize in ‘green chemistry’ and sustainable materials are looking for new ways to extract the glycosaminoglycans [GAGs] proteins found in egg shells. Many biomedical applications use GAG and they could prove to be beneficial to the pharmaceutical industry.

One way the team hopes to use the egg shells is to use them as fillers to bulk up different kinds of plastic.

But overall, the goal is to use egg shells in packaging to protect egg products. According to iNet this type of recycling gives a second lease of life to the egg shell in the very role it was created for and makes this a true case of recycling.

“Egg shell is classified as a waste material by the food industry but is in fact a highly sophisticated composite,” said Food and Drink iNet director Richard Worrall. He then adds: “The scientists at the University of Leicester have identified a number of uses for egg shell waste and the Food and Drink iNet is very pleased to support a ‘Collaborate to Innovate’ research project to examine egg shell recycling solutions. This could have potential benefit on many levels, both for food manufacturers and a much wider industry.”

So where are all these eggs coming from?

The project plans to get egg-related companies in the area to help out by giving the team small and medium-sized eggs.

One company, Just Egg, a hard-boiled egg and mayonnaise manufacturer uses around 1.3 million eggs every week. Those 1.3 million eggs create about 10 tons of egg shells. The cost of sending about 480 tons of shells to the landfill adds up and costs the firm about £30,000

Managing director Pankaj Pancholi said the research could bring big benefits to the food and drink sector.

“If I wasn’t spending the £30,000 a year on landfill costs I could employ another worker or two part-time workers, or invest that money in R&D and innovation,” he said. “It would be great if the egg shells could ultimately be recycled to be used in the plastic packaging that we use for egg products, like our new hard boiled eggs in packs. This is a really exciting project.”

Farmers Weekly adds:

“The iNet-funded project aims to develop and validate the pre-treatment process of the eggshell needed to make it sterile; develop a method for the extraction of glycosaminoglycans from eggshell and analyze the products obtained; develop a post-treatment process to convert the eggshell into a starch-based plastic; test the mechanical properties, including the strength of the new material and make a variety of materials to optimize the eggshell loading and particle size.”

Source: Farmers Weekly

 

Study of Arm Amputees Finds that Improvements are Needed in Medical/Healthcare Packaging

April 5th, 2012

The opportunities are endless for healthcare companies to differentiate themselves in a competitive market by making the product to use with one hand. By being convenient for one-handed use, this convenience packaging could be a top competitor in the healthcare packaging industry. Convenience is the killer app, according to a unique new “One Handed World” study.

THERMOFORMING Study of Arm Amputees Finds that Improvements are Needed in Medical/Healthcare Packaging

The study found that that the convenience of using one-hand creates delight and loyalty in consumers. A product that is easy to use with a single hand has strong competitive advantage in the marketplace, which can lead to an increase in profits and loyalty from customers. With about 79 million Baby Boomers in our midst, this is not an opportunity that can be easily ignored.

The “One Handed World” study was inspired by the increase in smartphones and aims to reveal insights about future healthcare packaging needs since this extreme user group provides a glimpse into the changing ways that humans interact with a wide variety of products, including packaging.

Multitasking is nothing new, we do it all the time, but the dramatic increase in smartphone usage is creating a permanent change in human behavior and is something that designers and manufacturers simply can’t ignore.

While reading the title, you may have asked yourself, “Why arm amputees?”

Well, the study investigated how one-arm amputees interacted with, and how they were challenged by, nearly 250 everyday products, including the packaging, across 18 different categories. Then, two-handed consumers were surveyed to understand how they spent their days and how they fared with the same items.

In all, 25 percent of the amputee respondents reported that everyday items were difficult to operate with one hand, with the degree of difficulty increasing with the complexity of the task. Even two-handed consumers reported that they had difficulty opening or using some products, even when both hands were fully available. In some cases, two-handed respondents reported more difficulty than the amputees.

Results found that the two-handed consumers spent about 40% of their day with having one hand occupied. As a result of this occupation, the two-handed consumers attempt to interact with products and packages by using a single hand or finger.

One-arm amputees provide the research with a preview of this shift in overall consumer behavior and how consumers are using products and how often they struggle. With the results of the study, marketers and designers can better understand what the future consumer may need, and create a new design to meet those needs.

Source: Healthcare Packaging

Blister Packaging and Other High Visibility Markets Projected to Exceed $37 Billon by 2018

March 29th, 2012

THERMOFORM blister 300x225 Blister Packaging and Other High Visibility Markets Projected to Exceed $37 Billon by 2018

Global Industry Analytics(GIA) recently announced in a press release the comprehensive global report on the Blister and other high visibility packaging markets. Overall, the market for blister packaging and other high visibility markets is projected to exceed in $37 billion by the year 2018. This number comes from the rising demand from developing markets, especially in countries China, India, and Brazil. Factors that affect this number include population increase, sustainability issues, household and demographic variables, consumer spending patterns, retail sales, and the overall economy growth. The food industry remains as the largest end-user of blister and high visibility packaging, but the pharmaceutical/medical industry is also expecting future growth.

There was a steep decline in the packaging industry in 2008-2009 due to the global economic meltdown, this meltdown had an obvious impact on the blister and other high visibility packaging market. In 2010, there was some pickup in the market growth but the demand was weakened by the debt crisis Europe was facing at the time that was caused by the economic conditions in North America. With the economy gaining more momentum and slowly improving, the packaging industry is expected to see growth through the recovery as consumer confidence increases. The industry is also starting to notice a shift among manufacturers in emerging countries. Developing markets are seeing fast paced growth, especially in Asian countries. These smaller markets include Mexico, Indonesia, Australia, South Africa, Vietnam, Nigeria, Turkey and Poland, among others are steadily gaining prominence on the global platform. As these countries being to see increasing investment to infrastructure, housing sectors, urbanization trend, expanding healthcare sector, and steady economic growth, there emerges growth potential in packaging sector.

The food industry remains the largest user for blister and other high visibility packaging solutions due to its use for fresh produce, prepared foods, snacks, baked goods, meats, dairy and other food products. For a consumer, the use of high visibility packaging allows them to inspect the content without the need for handling, a factor that plays a vital role in enhancing consumer confidence pertinent to a specific product. Although the food sector continues to dominate the global blister and other high-visibility packaging market, the pharmaceutical industry is also getting more involved. Manufacturers are likely to change and shift towards low-cost blister packaging.

Source: SF Gate

 

 

Thermoforming vs. Injection Molding

March 22nd, 2012
THERMOFORMING product dev cycle 300x222 Thermoforming vs. Injection Molding

Image Source: Productive Plastics

Year after year, the thermoforming market continues to see positive growth over injection molding. So what is the difference between the two manufacturing processes?

Thermoforming is a single sided process, which means that only one side of the sheet is controlled by the tool surface at a time. The finished wall thickness is determined primarily by the design of the component part. Thermoforming is typically selected for use for production quantities of 250 to 3000 annually. It offers lower tooling costs, rapid product development cycles, and allows for parts with color and texture.

Injection molding on the other hand may be used to make plastic parts for similar applications. Very high tooling cost is typical for injection molding, but for large quantity orders, the cost per part is reduced.

Expenses is one of the main reasons that thermoforming is a better option over injection molding. Both processes require tooling and upfront costs which can be up to 80% less if using thermoforming on pressure forming versus the costs of injection molding.

There are many different factors that affect the prices between a thermoform and injection molding. Thermoformed molds only need to be machined aluminum or cast aluminum, rather than machined steel. Also, a majority of the thermoforming molds only need one mold half (as well as a pressure box for pressure forming) instead of the injection moldings requirement for two matched molds.

The difference in the amount of tools needed for thermoforming processes to create a project results in differences in lead times faster deliveries, lower prototyping costs, and allow for more time on final design changes and modifications. The added benefits of having quicker prototyping capabilities means that the thermoforming can ensure maximum flexibility and even visibility of the product definition before it is finalized. Injection molding processes can create negative conditions such as ejection marks, gate marks, and porosity, which thermoforming can eliminate.

Source: Lormac Plastics

 

 

A Simple Definition of 3 Types of Thermoforming

March 14th, 2012

Here’s a simple way of understanding 3 main types of thermoforming:

1. Vacuum Forming- A vacuum is formed between the mold cavity and the thermoplastic sheet. The vacuum pressure forces the sheet to conform to the mold and form the part shape.

vacuumthermoforming 300x225 A Simple Definition of 3 Types of Thermoforming

2. Pressure Forming- Pressure forming is an addition to the vacuum forming process. On the back side of the thermoplastic sheet, pressure is applied to help force the sheet onto the mold. The pressure is greater so the additional force can thermoform thicker sheets as well as creating finer details and textures.

pressurethermoforming 300x225 A Simple Definition of 3 Types of Thermoforming

3. Mechanical Forming- The thermoplastic sheet is mechanically forced into or around the mold by direct contact. Air pressure is not used at all. A core plug is used to force the thermoplastic onto the mold.

mechanicalthermoforming 300x225 A Simple Definition of 3 Types of Thermoforming

AmberWorks Looks To Improve Bioplastics

March 7th, 2012

bioplastics AmberWorks Looks To Improve Bioplastics

A lot of interest in PLA and other bioplastics has faded in the last year or so. The concept received a lot of coverage in recent years as environmental concerns have continued to mount. But if you keep up on it, you’ll notice that the talk has all but stopped. But why? In theory, bioplastics are great but it’s quite evident that the technology isn’t there to allow them to complete with their other plastic counterparts. Cost, durability, and sensitivity to extreme heat are the glaring issues.

With that said, NatureWorks and BioAmber have teamed up to start a joint venture called AmberWorks. The goal? To develop new compounds that will expand the property range of bioplastics.

The companies are targeting biodegradable food service products such as injection molded cutlery and thermoformed cups, lids and clamshell containers. Samples have been developed already for thermoforming and injection moulding and the material is approved for food contact by the FDA. The new materials expand NatureWork’s Ingeo properties in terms of flexibility, toughness and heat resistance.

No word on the timing of when it will officially come to market. Conventional wisdom says that eventually the technology will be developed so that bioplastic can conceivably become a competitive plastic product in the thermoforming industry. It’s now just a question of how long.