MACHINERY | THERMOFORMING
Right: Ray Products
thermoformed this EV charging station part from from Sekisui Kydex sheet
Kydex 1100UV – the sheet material used – meets
UL 94 V-0 flammability and UL 746C F1 weather- ability requirements while providing UV resistance, durability in extreme conditions, and in-mould colour, which eliminates the need for painting. The final 11-part enclosure was engineered for
easy assembly with minimal attachment points, streamlining installation and eliminating the need for secondary processes. This design approach enhanced assembly efficiency and contributed to the long-term structural integrity and reduced maintenance costs for the client. Using pressure forming, Ray Products made several thousand units with consistent quality.
Below: SML says its PP sheet lines can now make foamed sheet at high volume
Foamed PP SML says that its PP sheet lines are now equipped to make foamed sheet at high volume. Emerging EU regulations are driving the need for innovative, forward-looking packaging solutions – such as foamed PP sheet as an alternative to EPS for food packaging, it says. “We have optimised and upgraded specific components of our PP sheet lines for manufactur- ing high volumes of premium foamed sheet,” said Martin Kastner, R&D engineer at SML. “We did this without compromising the lines’ high efficiency and product quality with regard to classic PP thermoforming sheet.” With SML’s sheet lines, the total density of PP foamed sheet that can be achieved, is as low as 0.55 g/cm³, referring to a sheet made from standard polymers with an A/B/A structure, consisting of 20% conventional PP in the outer A-layers and of 80 % foamed PP in the inner core layer (B layer). Compared with regular PP sheet, this corresponds to a reduction of 40%. “The lower material input results in significant savings for sheet manufacturers and in lighter packaging,” he added. The PP sheet line has a coextrusion system with a 180/33 single-screw extruder as the main extruder on which the foamed B-layer can be manufactured. It achieves a plasticising capacity of up to 1,250 kg/h with a mixture of virgin PP and up to 80 %
regrind. An HSE 75/37V semi-high- speed extruder serves as the co-extruder
(for the A-layers). The complete extrusion system of the line delivers a maximum plasticising capacity of up to 1,850 kg/h. For making foamed PP sheet, the screw of the
main extruder was given a special design. In addition, the extrusion system has a foaming technology package customised for PP in the melt pipes of the main extruder. Small quantities of inert gases such as CO2 or N2 – plus a nucleating agent in the melt – allows the creation of fine microcells in the core layer (B-layer) of the A/B/A sheet, says SML.
PET tray recyclability WM Thermoforming Machines is integrating new technology into its FC/FX steel rule die thermo- forming range to enhance the recyclability of mono PET trays and optimise the overall production process. The model now integrates a gluing system, padding system and Ausil’s AI-driven automated inspection system. The gluing system improves weldability without the need for PE laminates. This addresses recycla- bility challenges and maintains product integrity, reducing environmental impact. Additionally, the padding station that integrates liquid-absorbing padding is a crucial feature for sectors such as the meat industry, ensuring hygienic and practical packaging solutions. When integrating these technologies, manufac-
turers typically have two options: off-line and in-line applications. In-line integration is designed for high productivity, minimising space require- ments and manual handling while maintaining continuous production. This approach results in
better hygiene, improved quality control, and overall higher efficiency. On the other hand, off-line
14 FILM & SHEET EXTRUSION | March 2025
www.filmandsheet.com
IMAGE: SML
IMAGE: SEKISUI
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