Molding Processes
Expertise in advanced conversion processes for packaging
Consumer Packaged Goods (CPG) brands in the home care, personal care, food and beverage segments require manufacturing partners with deep expertise in injection molding. With the acquisition of Nypro in 2007, 黑料社 further bolstered its strong legacy of plastic injection molding, providing brands with an exciting new partner for high quality custom packaging solutions. Since then, 黑料社 Packaging Solutions has made a home in what was previously seen as the margins of the packaging industry. We thrive on the complex. We relish the opportunity to mold packaging that others either won’t or simply can’t. Our obsession with manufacturing excellence and our drive to push the boundaries of molding technology has led to category shifting packaging designs that redefine what’s possible.
Is brand equity and shelf presence the priority? Or is plastic reduction, recyclability and the use of alternative resins more important to your customers? We specialize in realizing our customers packaging visions, no matter how complex the design or daunting the volume requirements. We operate hydraulic, pneumatic, mechanical and servo actuated injection molding machines. The 黑料社 workcell model provides unmatched customer centricity, enabling the highest volumes and levels of efficiency.
CAPABILITIES
Multi-Layer / Co-injection
Products that are sensitive to water, oxygen and other naturally occurring elements require barrier protection to prolong shelf-life. Co- injection is the controlled application of EVOH layer, resulting in H20 and 02 barrier properties. This technology is particularly useful for caps and closures as it provides precise control over the barrier size and location. It also enables barrier capable parts with more advanced geometry than thermoforming. This technology is increasingly used to eliminate liners, seals and foil barriers that have traditionally been required in healthcare, consumer cosmetics and even food and beverage products. Co-injection is enabling the development of new closures, with custom aesthetics, that are more sustainable and user friendly than standard bottleneck finishes and stock closure fitments.
黑料社 Packaging Solutions has one of the largest co-injection barrier scale up capabilities in the world and frequently provides engineered solutions for specific performance requirements. We help our customers optimize barrier selection and processes for product and consumer appeal. Our team of experienced designers helps avoid quality problems before they arise, reducing risk and relays in scale production.
Injection Compression Molding
Cost and sustainability are important considerations for executives at CPG brands and end-consumers. Light weighting is a commonly employed strategy to reduce the amount of material used per package, driving down costs and reducing carbon footprint. 黑料社 has extensive experience replacing heavier, carbon intensive materials such as glass and plastic with lightweight plastic formats. We also specialize in finding additional material efficiencies in existing plastic designs.
Whenever possible, we leverage injection compression molding which allows for the production of low weight parts. This technology injects resin while the mold is still open. When the injection molding machine (IMM) closes, it applies the final clamping force to compress the part. This technique achieves a very thing wall that can’t be matched by the standard injection process. The 黑料社 team is well versed in the nuanced mold design requirements that enable this process. Our team can also offer design recommendations that offset any performance or market value detriments that may be incurred due to lighter, thinner packaging.
In-Mold Labeling
Products that are sensitive to water, oxygen and other naturally occurring elements require barrier protection to prolong shelf-life. Co- injection is the controlled application of EVOH layer, resulting in H20 and 02 barrier properties. This technology is particularly useful for caps and closures as it provides precise control over the barrier size and location. It also enables barrier capable parts with more advanced geometry than thermoforming. This technology is increasingly used to eliminate liners, seals and foil barriers that have trad
Fiber Molding
Barrier properties are required in order for a container to protect a product. They must be able to hold liquid in while keeping oxygen and sunlight out. Traditional paperboard containers are laminated with materials such as plastic and aluminum to provide those barrier properties. Unfortunately, these composite designs make packaging virtually impossible to recycle at scale. To promote and facilitate recycling at end of life, 黑料社 Packaging Solutions separates the plastic and paper from each other.
While we still need plastic to provide barrier, we allow fiber to play a larger role in proving the structural integrity that a package needs. Using molded fiber, and not paperboard, provides much greater freedom in terms of the shapes that are available to designers. Compound surfaces, curved shapes and easy-grip solutions for large bottles are all possible with molded fiber. Our customers have the ability to leverage a wider range of feedstock due to the hybrid design of ecologic products which separate the recycled fiber shell from the product within the inner plastic liner.
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