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