Ultra-Thin-Walled Container by Injection Molded Technology – Toppan

April 4, 2021February 6, 2023 Vihaan Nagal 1 Comment

Supercritical fluid Technology

Toppan Printing, a Worldwide leader in communication, security, packaging, décor materials, and electronics solutions, has used supercritical fluid with injection molding technology to produce an ultra-thin-walled container 30% thinner than traditional injection-molded plastic.

SUSTAINABLE-VALUE container

The unique container is an extension to Toppan’s “SUSTAINABLE-VALUE™ Packaging” lineup, which is part of the newly started “TOPPAN S-VALUE™ Packaging” range. It targets combined value for society and fulfilling living, and the samples will be made possible in Japan from February 24 for manufacturers in the foods and toiletries sectors.

Sustainable Development Goals

The Sustainable Development Goals (SDGs) and other environmental preservation and resource-saving actions are gaining momentum globally. The difficulty of marine pollution caused by plastic waste has indicated a focus on packaging with decreased environmental impact.

A decrease of plastic resin using injection molded containers needs the minimum possible thickness when molding is produced and has presented challenges in costs, durability, and mass production feasibility. Thermoforming has usually been considered better for creating containers that need thin walls, but it does not offer the exact scope of design possibilities as injection molding.

Comparison of a sample using conventional injection molding technology (right) and Toppan’s new ultra-thin-walled injection-molded container (left)
©Toppan Printing Co., Ltd.

Toppan has formed a new technology to beat the conventional boundary of injection molding and form products controlled with reduced thickness near that achieved by thermoforming. A supercritical fluid is dissolved in molten resin to ensure that it efficiently gives every injection mold corner. It involves lighter containers with thinner walls that can be produced while securing freedom for shape and design.

Thickness Range

Due to the blend of supercritical fluid and Toppan’s unique molding technology, the wall of injection-molded items’ thickness can be reduced by approximately 30%, from 0.5 mm to 0.35 mm. It can decrease plastic consumption by up to 30% and lower CO² emissions blended with resin manufacture. In the state of a prototype margarine tub, CO² emissions during production decreased by about 20%.

Option for Biomass and Eco-friendly plastic

As the resin’s fluidity shot into the mold is advanced, the technology also allows the use of further eco-friendly plastics, such as biodegradable and biomass polyethylene resin. It has earlier been challenging to mold. Despite the decrease in thickness, strength is sustained, as is the extent to which design containers in a wide variety of shapes match their use.

“This new technology allows the production of containers that give all the advantages of conventional injection molding but with decreased impact on the environment,” said Toshiaki Kakemura, GM of Plastic Development in Toppan’s Packaging Solutions business. “We will increase sales to manufacturers of food and toiletries and proceed to drive sustainable solutions for society and growth for our customers’ business through the TOPPAN S-VALUE™ Packaging range.”