In-House Tooling
40 Years’ Tooling Design and Manufacturing Experience
Having our own internal tooling manufacturer means that our customers enjoy a true end to end new product development service experience.
Customers are in control of the whole process from design to manufacture, and because there are no third-party requirements, you have full peace of mind that sensitive designs are fully protected until patents and launch dates are achieved.
Auto De-Nesting and Heat Sealing Heads
We have a vast amount of knowledge and experience in auto de-nesting machines and heat sealing heads, both of which are heavily used within the industry for the separation of trays and top film sealing.
We are happy to visit our customer production sites in person to secure the exact measurements for these critical machine parts. This significantly reduces lead times and ensures we get it right first time, every time.
100% On Time In Full
Since all our customer tooling technical information is held readily available in-house, we are able to support our thermoforming divisions to meet orders on time and in full through quick turnaround on any tooling modifications, repairs or upgrades.
Process
We use industry-leading design software to create a 3D model of the desired packaging tray for customer feedback, following which a sample is produced for approval.
Through a cutting-edge CAD package, we then design the appropriate tooling required for mass production of the finalised tray. At this stage, our engineering team are able to address any additional features or potential issues that may arise before going into production, keeping timelines tight and costs in check.
Technical drawings are then released to the toolmakers, who use a computer-aided manufacturing platform to create the accurate tray profile. Having a computerised mould on file means that we can re-machine and repair tools due to wear and tear at a moment's notice in the future, significantly speeding up potential downtime.
Thermoforming: Tooling Design and Modification
Thermoforming is a process of shaping plastic sheets into various forms, such as trays, containers, and packaging. The quality and efficiency of thermoforming depend largely on the design and performance of the tooling, which is the set of moulds and equipment used to form and cut the plastic.
Tooling Lead Time and Setup Process
The tooling lead time is the duration from the approval of the tray design to the completion of the tooling. It varies depending on the complexity and size of the tooling, which are influenced by several factors, such as:
- Tray design: The shape, size, and features of the tray affect the tooling design and manufacturing.
Simple Design
Average Complexity
Complex
- Tray depth: Deeper trays require plug assist, which is a device that helps to stretch the plastic sheet into the mould cavity.
- Sealing method: Heat-sealed trays need extra cooling to prevent the plastic from sticking to the mould.
- Number of tray impressions: The more trays that can be formed and cut in one cycle, the larger and more complex the tooling will be.
- De-nest type: The way the trays are stacked after forming and cutting also affects the tooling design. AB and ABC stacking, where the trays are alternately flipped, require more complex handling equipment than standard stacking.
Forming Station
Cutting Station
Stacking Station
- Material type: PP (Polypropylene) and PET (Polyethylene terephthalate) are two common types of plastic used in thermoforming. PP has a high shrinkage factor, needs higher temperatures to form, and is less dimensionally stable than PET. These factors make PP tools more complex to design and run.
Our tool manufacturing facility based in Arklow can produce a small and simple tool in three weeks and a large and complex tool in eight weeks.
Tooling Impact on Production
Tool efficiency is critical for long-term production. A well-designed tool will:
- Use less plastic and energy in production
- Run at a fast cycle speed
- Run with the minimum amount of downtime for repair and maintenance
- Be simple to set up for different tray design
Tooling Modification for Changes in Packaging Design
Sometimes, changes in packaging design are required to meet customer specifications or market demands. The ease and cost of tooling modification depend on the type and extent of the change.
A full toolset consists of several stations, such as forming, cutting, stacking, and sealing. To change a tray design with the same cut size (that is, a change of depth or rib pattern), only a base tool change is required.
Tooling Modification Costs and Time
The costs and time associated with tooling modification will be affected by the same factors that affect the tooling lead time and design. Another type of modification is to improve the production performance of a tool after the trial run. These modifications are done in consultation with the tool setters in thermoforming, who have the expertise and experience to optimise the tooling performance. Production performance modification can also be done later in the life of a toolset as improved tooling designs are developed.
