begg & co thermoplastics ltd
DESCRIPTION
Begg & Co Thermoplastics Ltd. Creative Masterbatches & Raw Materials. Mould Perfect in Thermoforming Applications. Darren Wadsworth July 2006. Case Study Thermoformed Meat Trays. 27% Productivity Improvement. PPCo Multi Layer Meat Trays Off-line thermoforming Benefits - PowerPoint PPT PresentationTRANSCRIPT
Begg & Co Thermoplastics Ltd.
Mould Perfect in
Thermoforming Applications
Creative Masterbatches & Raw Materials
Darren WadsworthJuly 2006
Case Study Thermoformed Meat Trays
PPCo Multi Layer Meat Trays
Off-line thermoforming
Benefits
• Improved productivity cycle reduced from
7.5 to 5.9 sec• Less warpage (bottom of
containers flat)• Improved trimming and
quality
0 2 4 6 8
Control
MouldPerfect
Cycle Time (sec)
27% Productivity Improvement
Tc = 116 C
Tc = 125 C
Tray at 5.9 sec
Tray at 5.9 sec with Mould Perfect
Case Study Thermoformed Margarine Container
PP Homo MFI 3
Margarine Container (9 g)
In Line Thermoforming Benefits:
• Improved productivity – cycle reduced from
19.1 to 20.8 cycles / min
• Improved stiffness / top-load & easier stacking of parts.
18 18.5 19 19.5 20 20.5 21
Control
MouldPerfect
Productivity (cycles / min)
9% Productivity Improvement
Case StudyThermoformed Lids
PP homo / PP co Random Blend(75/25)
Thermoforming
Benefits
• Improved quality, less warpage with flatter lids
Mould Perfect
0.78
0.9
0.7
0.8
0.9
1
Control Mould Perfect
Sh
rinka
ge
Iso
tro
py
(MD
/TD
)
Shrinkage Isotropy Closer to 1 = Less Warpage
Control
Case Study Thermoformed Cups
PP homo MFI3
(with 50% regrind)
Drink Cups
In Line Thermoforming Benefits
• Improved productivity –cycle reduced from
21 to 27 cycles / min
• Improved stiffness / top-load & easier stacking of cups.
0 5 10 15 20 25 30
Nucleated
MouldPerfect
Productivity (cycles / min)
29% Productivity Improvement
Case StudySheet Extrusion
PP homo (with 35% regrind)Sheet extrusion(800µm x 670mm)
Benefits
• Improved productivity – improved output from 10.8 m/min to 12.5 m/min.
9.5 10 10.5 11 11.5 12 12.5 13
Nucleator
MouldPerfect
Extruder output (m/min)
15% Productivity Improvement
This sheet was used to make the parts described on the next slide.
Case Study Thermoformed Food Storage Containers
PP homo (with 35% regrind)
Thermoformed Sandwhich box
Benefits • Improved productivity –
cycle reduced
from 2.6 to 2.3 sec• Improved quality – less
warpage with Mould Perfect (on bottom of part)
2.1 2.2 2.3 2.4 2.5 2.6 2.7
Nucleator
MouldPerfect
Cycle Time (sec)
13% Productivity Improvement
Case StudyThermoformed Lids
PP homo MFI 2In Line Thermoformed Lids
Control (non-nucleated)Nucleation AgentMould Perfect
Benefits
• Improved quality – flat parts
Control Nucleators Mould Perfect
0.8
0.91
0.7
0.8
0.9
1
Nucleator Mould PerfectSh
rinka
ge
Iso
tro
py
(MD
/TD
)
Shrinkage Isotropy Closer to 1 = Less Warpage
Nucleation Agents cause warpage due to uneven shrinkage