The whole process of making plastic packaging products is indeed a highly creative and intellectually enticing challenge for us. We are always looking for new, better concepts of product storage, protection, and shipment.
New product development is a process which requires a lot of professional interaction between our staff experts and our clients. We assist our client in generating new ideas and new concepts of packaging. Together, we proceed from making a model or a prototype of future packaging all the way to making a mould and manufacturing ready-to-go plastic packaging.
Our experience and competence in manufacturing blow molding plastic packaging products helps us to find the best packaging solution for our client. That includes developing the optimal design, choosing the right type of plastic, optimizing the product mass, rigidity, and resistance – to arrive at the best type of packaging that fully suits our client’s needs.
Mass production is of course the key to our business success. The efficiency of the manufacturing process directly influences the product quality, the overall production schedule and, ultimately, the profitability of every client order. That is why we are always focused on perfecting the manufacturing process. It involves a continuous investment in state-of-the-art plastic packaging production lines, and a lot of everyday effort to enhance the efficiency of the production process.
GAMMAPLAST Corp. puts a special emphasis on the following aspects of the business process:
PET packaging form is affected not only by the design conceived by the customer. It is developed and approved, taking into account the potential of extrusion blow molding equipment in the production of packaging. Any PET packaging form must necessarily correspond to the production technology of the customer's product itself, for which PET packaging is designed. In order to choose the best option of PET packaging form, it is necessary to take into account the following 3 aspects:
Once the PET packaging form has been approved by the customer and the technology department, you can proceed with the label design.
Modern graphic design allows the customer and designer to implement almost any idea. The designed image can be applied to the label in a number of ways. The most popular of these is the Flex method.
First of all, the design of a PET package begins with elaboration of the preform and choosing the type of corking. Half-finished PET bottles, tins, vials and other containments can weigh from 16 to 150 grams. At the same time, the size and, consequently, the cost of the packaging itself (directly or proportionally) depends on the weight of the preform.
A high-speed rotary SBM machine is used in the flow production of PET packaging. Preforms are loaded in its main distributor hopper, then they are moved to the dispenser. There they automatically take the right position needed for getting into the main system. The movement is carried out by the lifting tackle.
The preforms are taken to the top by other means – by a spiral lift. Here they take the right position between each other and reach the working compartment, where they are fed by the gear wheel.
The preform is then fixed by the wheel knuckle at the ring on the neck of the bottle, turned over and fed to the heating carousel. This carousel takes preforms through the heating chamber, till they become soft and ready for the forthcoming blowing. In this chamber the preform is heated evenly, because it constantly rotates around its axis.
When the half-finished bottle leaves the heating chamber, for some time it remains still in order to equalize the temperature. After this half-finished bottles are fed into the open molds, where the bottles are blown out.
The molds are placed close to the heating chambers. Once the mold is closed, the preform begins to elongate and gets blown out. For elongation a core pin is inserted through the neck of the bottle to its bottom. The depth of core pin lowering into the bottle depends on the shape and size of the designed bottle.
The blowing itself takes about 1 second and is performed under the highest possible pressure. Afterwards the bottle gets its final shape. The core pin is taken out, the bottle is cooling down, and the mold opens for the take out of a finished bottle.
PP is a polypropylene, its feature is translucency. It is used to package syrups, yogurts. Resistant to high temperatures, relatively safe.
PS - used to manufacture coffee glasses and fast food packaging. The material is not designed for storage of extremely hot products, since at high temperatures it can release toxic compounds.
PC - used as a packaging for bottled water. It is classified as a dangerous type of plastic, therefore it is not suitable for storage of food.
PET - raw material, which can be used only once.
HDP - the most harmless and safe type of plastic for human health. Can be used for packaging of different food.
PVC - is designed for packaging vegetable oils. In not safe to human health because it contains substances that affect endocrine profile.
LDPE - used for water packaging, is not suitable for storage of food.
Taking into account client requirements and products specifics, we offer several options for the packaging solution
In accordance with the packaging solution chosen by the client and the product blueprint that had been approved, we make the press-form. Per client request, and before making the press-form, we can make a 3-D prototype of the future packaging product which replicates design and dimensions of the product that eventually will be mass-produced.
When the mould is made and the test batch of the packaging is approved by the client, we get ready to launch mass-production of packaging to fulfil client’s orders.