Case study 7

Increasing product efficiency

 

Starting situation

To date, our customer has been using a deep-drawn tub made of polystyrene.

Industry

Dairy products

Strategy/reason

Increase in manufacturing efficiency, attractive look/feel

Task

To replace the existing tub with an injection-moulded tub made from PP. The look and feel should be high quality. The filling system should not have to be modified.

Implementation

The big challenge was the requirement to use a bottom label as well as the IML side label. Since spraying on at the core side was not possible for space reasons, the bottom geometry and the spray-on geometry had to be specially designed. With the aid of computer-assisted filling simulation, flow aids were introduced in a targeted way and the hotrunner balancing system was balanced in such a way that even filling was achieved without the risk of reverse injection moulding of the IML label. The simulation results were confirmed on the basis of a sample tool, finally optimised and then incorporated in the series production tool.

Result

Because of the uniform wall thickness distribution in the injection moulding tool, an extremely stable and top quality tub was developed. The weight of the item was even reduced by using PP. The IML decoration underlines the high-quality overall impression of the tub.
Because of the outstanding repeat accuracy and the narrow tolerances in the injection moulding tool, the tub can be processed with a significantly higher number of cycles in the filling system.

Customer benefit

Because of the high-quality look and feel of the new tub, the tub has differentiated itself from competition products significantly at the POS. The use of PP instead of PS has considerable cost benefits. The performance and productivity of the filling line has been improved considerably. The consistently high quality has resulted in outstanding availability and stable production.

Result

Improvement to

  • Look&feel
  • Efficiency
  • Differentiation potential
  • Quality
  • Availability