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Large-part thermoforming is rapidly gaining ground as a replacement for labor-intensive thermoset processes. This trend is attributable to several factors which include the entrepreneurial vision of processors. Another factor is its appeal to the dunnage, appliance, marine and automotive sectors. Major resin producers are contributing their technological resources while materials suppliers are cultivating the technology as a viable growth segment with long-term potential for major resin consumption.

After a slow start, computer process simulation has attracted a handful of new suppliers and is building a critical mass of high-profile users. Radically new technology takes time to sink [...]

Resins manufacturers are enhancing and developing polypropylene (PP) grades that enable molders to produce improved food containers. Improvements include productivity enhancements in solid-phase pressure forming, high-flow PP and new additive mixing techniques that improve wall stiffness, clarity, gloss and processing part release. These grade improvements enable processors to optimize benefits of machine improvements such as in-line processing.

Who can afford to waste several hours or even a full shift to change over from one job to the next? Quick-change systems cost extra, but few thermoformers nowadays can [...]

Various technological innovations in thermoforming equipment have improved the manufacture of plastic parts. Modern thermoforming systems support increased repeatability and savings associated with time, energy and money. These equipment promote the establishment of performance properties, tolerances and specifications. They are also capable of heating plastic sheets according to a predetermined temperature to prevent warpage, degradation and material sag.

Rexam Containers responded to its customers' demand for glossy rather than satin-finished bowls from its rotary thermoforming process. Rexam developed its High-Pressure Rotary Thermoforming (HP-RTF), a breakthrough in the industry which has allowed them to penetrate a market dominated by injected molding processes. HP-RTF was first used on Pillsbury's frozen whipped toppings. Market potentials exist for health care and medical products and margarine containers., Rexam's new High-Pressure Rotary Thermoformer produces glossy rather than satin finish bowls printed by a new eight-color offset press. First application: Lightweight 8-oz HDPE bowls for frozen whipped toppings. When [...]

Higher-heat catalytic ovens offer many advantages over gas-fired ovens such as high energy savings and better temperature control. Realizing such advantages, many thermoformers and local utilities are offering rebates and other benefits to encourage old-oven users to convert such equipment to new catalytic panels. A discussion is presented on how catalytic heaters work.

The use of new resins and other materials, along with innovations in design and manufacture, is allowing the application of industrial thermoforming in a wider range of products.

Infrared laser technology offers an efficient and environmentally friendly method of bonding thermoplastics. Innovations in the delivery of laser power are making infrared lasers highly suitable for a wide range of plastics processing applications, including transmission gear welding and cutting. Two of such devices that are growing in popularity are solid state lasers and fiber optic beams, which make various bonding and surface treatment processes possible.

Thermoforming's key role in the world's first all-plastics car was among the biggest news for the record crowd of nearly 1300 that attended the 8th annual SPE Thermoforming Conference and [...]

Coralfoam has developed a new process combining injection molding, foaming and thermoforming that allows part weights typical of thermoforming to be achieved while getting excellent economics and uniform wall thickness. The process, known as InjectForm II, is a variant of the company's two stage process. One of the first products is a margarine tub that is 40% lighter that other conventional tubs. Other potential applications are flowerpots, drinking cups and deep-draw containers.

Few thermoformers have their process as well wired as this Midwest firm. Its success at raising quality and cutting costs shows other sheet formers that it's time to take a [...]

Thermoformed plastic cups are becoming the popular choice for yoghurt producers as the cups are thinner and lighter.

New methods of trimming in thermoforming processes in web forming and sheet forming operations have increased production and reduced costs. New advanced equipment makes this possible.

The roll-stock thermoforming technology exhibited at the National Plastics Exposition 1997 has focused on in-line or direct-extrusion production systems for front-end sheet extrusion. Thermoforming processors are aware of the cost-advantages of purchasing a complete pre-engineered manufacturing cell instead of putting together separate pieces of equipment. OMV-USA of Genoa City, WI, for instance, recorded three orders of its D140/E74.2 in-line sheet extrusion/thermoforming systems during the show.

QuesTech Packaging Inc has developed a thermoforming process for deep-draw barrier containers. The Newport News, VA-based plastics processing company, which plans to license the process, claims the system is capable of reducing scrap from 50% to 15% and performs better than existing thermoforming methods for manufacturing specialty containers. The process involves the formation of precut blanks in a near melt-phase but semi-solid state.

CAD/CAM programming of five-axis CNC trimmers/routers and a new device for quick release of plug assists without removal of the mold were two interesting developments that attracted a record 688 [...]

Communications Instruments Inc. (CII) has been able to substitute its polystyrene trays which stacks its electronic relays with static-dissipative vinyl trays. The new stackable trays reduced per-tray costs, lessened loading time, are more aesthetically attractive and do not require opening the package to identify its contents. There have been positive reactions to the thermoformed trays from CII customers., Stackable vinyl trays thermoformed by Blue Ridge Packaging achieve the mil-spec static control that Communications Instruments Inc. requires for its electronic relays sold to defense contractors. When the engineers at [...]

What's said to be the world's first system for in-mold labeling on a cut-in-place thermoformer has been operating for about a year at a Dutch packaging plant making margarine tubs. [...]

Recession is the mother of a lot of ingenuity, and one of the more fertile areas of plastics development today is twin-sheet thermoforming. Conventional single-sheet thermoforming is often called a [...]

Its not often that a printer invents a new printing technique. But that's what happened at GJ. Haerer, a 60-year-old sheetfed lithographer located in Clifton, NJ. Over a three-year period, [...]

Geo A. Hormel and Co introduced cold cuts packaged in reclosable thermoform in response to customer demand for convenient and healthy packaged foods. The zippered package of flexible thermoform also can double as a container after the initial opening. The package is composed of an 8-mil forming web with eight layers consisting of nylon and a coextrusion of ethylene vinyl alcohol and ethylene vinyl acetate., Light & Lean 97 julienne-style meats are ready to use, then store in a handy, reclosable, preprinted thermoformed pack with a 60-day refrigerated shelf life. Consumer demand for healthy and [...]

The plastics industry is gradually shifting to the use of a new type of catalytic heaters in various thermoforming processes. This heaters, which relies on natural gas, are flameless and are safe to operate since fuel oxidation is well regulated. They use infrared energy to heat the absorbing material or medium, thereby, preventing the unnecessary dissipation of energy into the surrounding air., Faced with higher and higher electric bills and escalating demand charges, a plastics thermoforming company in Michigan started to look at alternatives to the quartz electric heaters it was using [...]

Rohm and Haas, Co of Philadelphia has developed a new acrylic modifier that improves the thermoforming properties of polypropylene (PP) sheets. The acrylic mofifier enhances the PP's physical properties without altering the material's impact strength by acting as a nucleator. Acrylic-modified PP sheets have lower and more uniform melt pressure and increased strectchability. They also minimize the overall cost of the thermoformed part.

With an eye to potential applications in auto fuel tanks and appliances, Portage Casting & Mold Co., a thermoforming toolmaker in Portage, Wis., is developing innovative tooling that greatly improves [...]

Thermoforming Several new machines introduced at NPE bring extra flexibility to custom and captive formers. For one, John Brown Inc.'s Brown Machine div., Beaverton, Mich., displayed the first of its [...]

Hitek launches new generation moulder Australian thermoforming machine manufacturer Hitek has launched upgraded container-moulding equipment which uses the company's cuspation dilation (CD) technology, writes Juliana Koranteng. The first Intermittent Process [...]