How the THERMOFORMING PROCESS works? - Factories

Summary

The video explores the thermoforming process used to create various plastic packaging, highlighting its complexity and precision. It starts by showcasing the design and tooling stages, where packaging projects are initiated and the necessary molds are created using CNC machines. The process involves heating, stretching, and molding thermoplastic material to form packaging, followed by cutting and stacking. The video also covers quality control, waste recycling, and the range of industries—food, cosmetics, pharmaceuticals, automotive—that use thermoformed packaging. The detailed steps emphasize the technology's importance in modern production lines.

Takeaways

• 😀 Thermoforming technology involves heating and shaping plastic film or sheets to create packaging, commonly seen on store shelves today.
• 😀 The thermoforming process starts in the product design department where packaging projects are conceptualized and initiated.
• 😀 After design approval, tooling is created in the CNC department using numerically controlled machines to produce molds and forming stations.
• 😀 The tooling consists of several key parts: the forming station, mold plug, assist, cooling system, cutting station, and stacking station.
• 😀 Vacuum holes of 0.4mm diameter are drilled in the molds to allow the thermoplastic material to be sucked into the mold surface during forming.
• 😀 For small packaging, the film is heated to around 200°C to become malleable before being stretched, shaped under pressure, and cooled to maintain its form.
• 😀 Larger thermoformed elements, such as polycarbonate sheets, are heated and then vacuum-formed into shape using a blow technique before being cooled.
• 😀 After forming, products are cut using a die-cut system, and robots place the finished pieces for further processing.
• 😀 The thermoforming production cycle includes eight different packaging types, with robots handling two cycles at once to ensure efficiency.
• 😀 A skeleton, or leftover material, is generated during production, which is ground up and reused in making new film.
• 😀 Quality control ensures the dimensions, friction coefficient, and other critical properties of the final packaging meet standards for industries such as food, cosmetics, pharmaceuticals, and automotive.

Q & A

What is thermoforming technology?

Thermoforming technology involves shaping a plastic film or sheet by heating it to a malleable state and then forming it into a desired shape using molds. This process is widely used in packaging production.

What is the role of the product design department in the thermoforming process?

The product design department is where all packaging projects begin. They create the initial design and specifications for the packaging, which are later used to prepare the tooling needed for production.

How is the tooling used in the thermoforming process prepared?

Tooling is prepared in the CNC department, where numerically controlled machines create precise molds. These molds include components like the forming station, cooling system, cutting station, and stacking station.

What is the purpose of vacuum holes in the tooling?

Vacuum holes, which are drilled into the tooling, allow the thermoplastic material to be sucked into the mold surface, ensuring that the material forms the desired shape accurately.

What materials are typically used in thermoforming, and what are their properties?

Materials such as polycarbonate and thin plastic films are commonly used in thermoforming. Polycarbonate, for example, is transparent and has high strength, making it ideal for packaging that requires clarity, like food packaging.

What are the main stages of the thermoforming process?

The main stages of thermoforming include: 1) Heating the plastic to make it malleable, 2) Forming the plastic into the desired shape using pressure and vacuum, 3) Cooling the formed product, 4) Cutting out individual items, and 5) Stacking and packing the finished products.

How is the thermoforming process adjusted for large products like polycarbonate sheets?

For larger products, such as polycarbonate sheets, both sides of the sheet are heated. Then, air is used to blow the flexible material into the mold, where it cools and stabilizes to form the final product.

What role do robots play in the thermoforming process?

Robots are used to pick up and place the formed products after they are cut. In high-speed production lines, robots may handle parts from two cycles simultaneously to ensure efficient processing and packaging.

How does the thermoforming process address waste management?

The thermoforming process generates 'skeleton' waste, which is the leftover material after the product is formed. This waste is recycled by grinding it into flakes and reusing it to produce new film.

What kind of quality control measures are used in the thermoforming process?

Quality control includes measuring the dimensions of the finished packaging, checking the coefficient of friction of the material to ensure it slides properly in automatic packaging machines, and inspecting the raw material for defects.

What industries use thermoformed packaging produced by Poli?

Thermoformed packaging produced by Poli is used in a variety of industries, including food, cosmetics, pharmaceuticals, technical, and automotive sectors.