Im-Pak Technologies has been set up to exploit the potential of a new thin wall moulding process developed by Coralfoam inventor Peter Clarke.
Im-Pak has received numerous enquiries from major food manufacturers and packaging suppliers. Now a new project is underway with one of the world’s largest food distributors.
The product is food pack where the customer was looking for a 20% weight reduction and a 25% reduction in cycle time. Im-Pak has already achieved major improvements for a customer of a similar product, reducing product weight by 20% and the cycle time by 40%.
“The whole point of Im-Pak is not about making small incremental improvements but making major reductions in weight and cycle time without altering the product’s appearance or durability,” says Peter Clarke.
“With the burden of the Disposal Tax in Europe, it’s essential that packaging is kept to a minimum. It’s not just the cost but also an environmental issue.”
Im-Pak is reputed to be unique in that it allows products to be designed in PP with flow length/thickness ratios of up to 500/1.
“With thermoforming or conventional injection moulding too much weight goes into the base, where it is just not necessary. With Im-Pak we can put the weight where you want it, to add structural strength to the product.”
Im-Pak is a mould technology that works by injecting a pre-measured dose of material via a ‘shooting-pot’ into the mould as it is closing. This forms a biscuit shaped plug of material in the base of the cavity, which is then impacted by the core.
There is no injection or hold time, as this takes place during normal closing. Material can be processed at much lower temperatures due to the lower resistance to filling. The process also allows manufacturers to use a wider range of polymers, such as extrusion or blow moulding grades.
The success of various prototype tools have more than proved the technology, and now Im-Pak are ready to move on to multi-cavity and stack tooling.