Polymer processing technology
As the different new packaging materials began to emerge so did the equipment and technology for their manufacturing and processing. Interconnection between these elements as well as the rise in purchasing power, change in customers’ habits and the development of new products all led to an increase of new goods that needed to be packaged and to a change in packaging types.
Thermoplastic (plastomers) – linear and branched macromolecules, better known as plastic, can be processed by means of: injection molding, extrusion, thermoforming, blow molding, rotational casting, film blowing and stretching etc.
Packsol production range covers four main processing technologies carried out using the following equipment:
- PET, PP and PS film extrusion (KUHNE co-extrusion lines)
- Thermoforming (Illig, Kiefel, GN, OMV)
- Injection molding as well as IML (In-Mold Labeling) (Husky, Netstal, Arburg)
- PET bottles blow molding (MagPlastic)
By combining these technologies, we are capable of supplying the market with the wide range of different custom made shapes and materials suitable for packaging food, pharmaceutical and beauty products. At the same time, we are constantly investing in new technologies, in buying new equipment and in widening our offer, because that is the only way to satisfy all our customers’ needs and ensure uniqueness and premium quality of their packaging.
Flat film co-extrusion
Flat polymer films or sheets are most commonly used in the process of thermoforming or vacuum packaging of finished products; they are manufactured in the process of continuous extrusion which can be roughly broken down into the following operations: crystallization and drying of amorphous polymer granulates (when dealing with hygroscopic materials); mixing the granulates with additives in a precisely defined ratio and then feeding the mixture into the extruder; the polymer mixture is subsequently heated, melted and plasticized inside the cylinder i.e. the worm and then it is being forced through a system of channels onto the flat sheet die heated to a precisely defined temperature; mixture exits the extruder as a thin, evenly spread single layer or three layer film; the film is cooled over the calender rolls and then transported through a system of rollers onto the reel where coils of different widths and diameters are formed.
Packsol is one of the regional market leaders with years of experience in PET, PP, PS and PE film extrusion. We use cutting edge German and Italian technology: KUHNE, OMV, SOMOS, VisMec to ensure premium quality of our products as well as high productivity and efficiency.
Thermoforming
Thermoforming is one of the most widely used processes for manufacturing thin-walled rigid packaging. The process of manufacturing PET/PS or PP vessels, cups or lids using mold thermoforming technology includes the following steps: pre-heating of flat films/sheets by passing them over or between the rows of heaters; preheated film is fed into an open tool; the tool is closed while at the same time air compressed to 4 – 10 bar is blown in pushing the film against the cool walls of the tool i.e. the mold shaping the film into a desired form while simultaneously cutting it off from the rest of the film. After cooling off, the tool opens and the finished product – the vessel is ejected.
In this manufacturing process we use single and three station machines from the following renowned equipment manufacturers: Kiefel, Illig, GN, OMV.
Injection molding
The procedure of thermoplastic processing by means of injection molding takes part in several steps: precisely defined quantity of thermoplastic granulate is heated, melted and plasticized inside the cylinder i.e. the worm, and then it is being injected under pressure through a nozzle and further through a system of heated channels or hot runners into the mold – the tool. After cooling off, the tool is opened and the finished product is ejected. Plasticized - molten mass should fill the mold as quickly as possible, and the pressure and the temperature should be adjusted to the material and the design so the homogenous structure is achieved preventing the product from being deformed later on.
In the process of manufacturing packaging by means of injection molding, we use cutting edge hydraulic machines ensuring efficiency, high productivity and uniform quality while saving energy at the same time:
- ARBURG machines 1500-470C, 1600-520S
- HUSKY HyPET120 PET preform injection machines
- NETSTAL Synergy 2400/900 can injection machines.
PET blow molding – biaxial orientation
The procedure of producing PET bottles by means of blow molding technology takes part in several steps: PET mass previously shaped in the form of tubes – preforms is fed into a thermal tunnel where it is being heated and then fed into an open tool; the tool closes, counter mold rods stretch the preforms while the high pressure (40 bar) heated air is being blown in, expanding the preform against the walls of the tool i.e. the mold – cold walls of the mold shape the preform into a desired product. After cooling, the tool opens and the finished product – the bottle is ejected.
Blow molding is done on two reliable and efficient Swiss made MAGPLASTIC machines. We produce bottles of different volumes, colors and shapes. We can produce PET bottle ranging from 200 to 2500 ml in volume, with a maximum production capacity of 2800 pcs/h per one machine.