Trexel and Bockatech Partner to Increase Benefits and Scope of Foamed Packaging Applications
- Published: October 04, 2021
Trexel has long been a pioneer in physical foaming technologies using its MuCell® technology. MuCell has been in commercial production for 20 years enabling lighter and more dimensionally stable injection molded parts. The company has recently been focusing on packaging, developing the P-Series, a MuCell system designed specifically for fast-cycle packaging applications.
The benefits include thinner wall molding from reduced material viscosity and substantially reduced injection pressure and clamp tonnage, unique design freedoms with the elimination of flow restrictions during cavity filling and the ability to pack end-of-fill features through foaming, and the ability to produce opaque packaging that can be recycled in the clear recycling stream.
Trexel has teamed up with Bockatech (UK) to further develop technologies that complement Bockatech EcoCore®. Products made with EcoCore use a combination of innovations — in materials, processes, mold design as well as component design — and are lightweight, insulated, strong and durable.
EcoCore significantly reduces the cycle time required, to a level like that of traditional unfoamed thin wall injection molded plastic components. This reduction, in combination with a cut in material brought about by the use foam, makes the process beneficial in terms of both cost and performance for many packaging applications. These applications include reusables, those that benefit from a thermal barrier and containers that require extra strength.
EcoCore containers are made by injecting a gas laden melt (typically polypropylene) into a mold quickly at high pressure. The mold is opened almost immediately after filling. Expansion is controlled by skins, formed on the inner and outer faces of the container walls by cooling, that have molten and foaming resin in the center.
Typically using EcoCore results in a weight saving of around 30 percent compared to traditional injection molded containers.
EcoCore was originally developed using chemical foaming agents, Bockatech is now working with MuCell as they are continuing to push the boundaries of what foam light weighting can achieve as well as applying it to other packaging forms.
Currently Bockatech is using Trexel’s MuCell in the development of innovative and more sustainable retail food packaging for one of the best-known U.S. food brands as well as caps for a leading FMCG brand in Europe.
For more information, visit https://trexel.com.
