Toppan develops ultra-thin-walled injection-molded container for plastic and carbon cuts
09 Mar 2021 --- Toppan Printing (Toppan) has combined “supercritical fluid” and its original molding technology to develop an ultra-thin-walled container roughly 30 percent thinner than conventional injection molded plastic.
The new container is an addition to Toppan’s “Sustainable-Value Packaging” lineup, which is part of the recently launched “Toppan S-Value Packaging” range. Samples are now available in Japan for manufacturers in the foods and toiletries sectors.
The UN Sustainable Development Goals (SDGs) and other initiatives aimed at environmental preservation and resource-saving are gaining momentum globally. The marine plastic pollution crisis has prompted a focus on packaging with reduced environmental impact.
Plastic resin reduction for injection molded containers requires the minimum possible thickness when molding is performed and has presented challenges for mass production costs and durability.
Thermoforming has generally been considered better for producing containers requiring thin walls, but it does not offer the same scope of design possibilities as injection molding, explains Toppan.
The Japanese global printing company has developed a new technology exceeding the conventional limit of injection molding to form products with a reduced thickness close to that achieved by thermoforming.
The technical process
Supercritical fluid is dissolved in molten resin to ensure it efficiently reaches every corner of the injection mold, meaning lighter containers with thinner walls can be produced while providing shape and design flexibility.
The thickness of the wall of injection-molded items can be reduced by approximately 30 percent – from 0.5 mm to 0.35 mm – by combining supercritical fluid and Toppan’s original molding technology.
This process also lowers CO2 emissions associated with resin manufacture. In the case of a prototype margarine tub, CO2 emissions during manufacturing decreased by about 20 percent. Innova Market Insights flagged “The Carbon Catalyst” as a top packaging trend for 2021.
As the fluidity of the resin injected into the mold is improved, the technology also enables the use of more eco-friendly plastics, such as biodegradable resin and biomass polyethylene, which have previously been difficult to mold, the company indicates.
Despite the reduction in thickness, strength is maintained, as is the scope to design containers in a wide range of shapes.
Comparison of sample using conventional injection molding technology (left) and Toppan’s new ultra-thin-walled injection molded container (right).
“This new technology enables the production of containers that offer all the benefits of conventional injection molding but with reduced impact on the environment,” reiterates Toshiaki Kakemura, general manager of plastic development in Toppan’s Packaging Solutions business.
“We will expand sales to manufacturers of food and toiletries and continue to drive sustainable solutions for society and growth for our customers’ business through the Toppan S-Value Packaging range.”
Tokyo Pack 2021
The ultra-thin-walled injection-molded container will be showcased at the Toppan booth (S1-12, South Hall 1) at Tokyo Pack 2021, held at the Tokyo Big Sight exhibition center from February 24 to 26.
In November, Toppan launched packaging that better retains the sensory and nutritional quality of meat and processed seafood kept in frozen storage.
Edited by Joshua Poole
