Extrusion Molding for Continuous Package Production

Method for manufacturing molded food packaging films with improved oxygen barrier and molding efficiency. The method involves laminating a thermosetting film onto the top and bottom of an EVOH-containing thermoforming film. This is done by extrusion lamination. The laminated structure is then compressed to form the molded packaging. The laminated construction provides improved oxygen barrier properties and prevents tearing or sticking during molding. The thickness of the EVOH layer is balanced in the molded container.

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Device and method for forming fiber-based packaging elements with improved forming capabilities compared to conventional fiber-based packaging. The device has a die with mold cavities, punches, hold-downs, and fixings. The method involves holding the fiber-based packaging in place with hold-downs, forming shapes by pulling into the mold cavities with punches, and reducing subsequent flow in regions with fixings that extend through the gap. This allows deeper forming of fiber-based packaging compared to just gravity forming.

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An 11-layer high barrier heavy packaging film blowing machine for producing strong, high-barrier films for heavy duty packaging applications like food containers. The machine has a mold with multiple layers of templates and connecting plates between them. Extruders feed plastic into the mold to create the film. The mold also has a cooling duct with multiple air outlets to cool and stabilize the extruded film. The machine also has features like adjustable bubble stabilization frames and synchronized spoke winding mechanisms to handle films of varying sizes. The extruder has multiple heating zones to properly mix the plastic. This allows making heavy duty, high barrier films with properties like load capacity for packaging applications like food containers.

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Method for manufacturing packaging containers using paper molds to reduce environmental impact and improve moisture resistance. The technique involves optimizing the molding process parameters like temperature, compression ratio, and time to distribute a larger amount of thermoplastic resin on the surface of the container rather than uniformly. This prevents moisture absorption into the core. By using less resin overall, the technique reduces environmental load compared to uniform distribution. The surface resin concentration is achieved by compressing the molded product at higher ratio and shorter time than standard. This pushes resin to the surface and suppresses migration back. The technique allows lower resin content while still improving moisture resistance.

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Method for producing molded pulp packaging units like egg cartons that are stronger, lighter, and compostable. The method involves using a specific process to refine the molding slurry material made from recycled paper fibers. This process involves extruding the slurry through a twin-screw extruder instead of conventional refining methods. The extrusion step increases the fiber length and improves dryness, resulting in stronger and lighter packaging units. The longer fibers also allow better adhesion of laminated layers onto the packaging. The compostability is maintained by using biodegradable materials like biodegradable aliphatic polyesters in the laminated layers.

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Method and apparatus for manufacturing a dispensing portion for a container, like a crushable tube package, that can be easily and productively manufactured. The dispensing portion has a nearly parallelepiped shape that is formed by compressing a continuous polymer extrusion. This avoids the complex step of cutting annular doses like in prior methods. The parallelepiped shape allows simple cutting and transport without deformation. The molding orientation is lateral to the dose layers, enabling simultaneous molding of multi-layer doses. This avoids separate assembly of pre-processed elements. The membrane on the dose can be removed downstream of molding to open the dispensing path. The container neck has a zone for use and a neck surrounding the dispensing path. The polymer layers at the free edge appear there, enabling bonding of a sealing film for better barrier properties.

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A one-time forming device for making fresh-keeping packaging trays for fruits and vegetables that reduces production costs by eliminating multiple processing steps. The device has an upper mold assembly with an injection extrusion unit to fill the tray cavities with material. The lower mold assembly has clamps that initially form the tray sides. A rotating mechanism expands the lower mold to separate the tray partially. A guide fan cools the tray to solidify it. This allows one-time molding of the tray in the device instead of multiple steps like injection molding, cooling, trimming, and cutting.

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A process to make eco-friendly packaging boxes using paper and biodegradable plastic that can be formed in a single step. The process involves extruding biodegradable plastic into a film, then sandwiching it between paper layers using forming rolls. The plastic film is melted between rolls to bond it with the paper. This allows making the boxes in a continuous process without separate plastic molding steps. The biodegradable plastic used is a blend of materials like polyethylene, emulsified silicone oil, lactose, lubricant, phosphite, solubilizer, biodegradable plastics, and degradable substances.

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An apparatus for manufacturing a plastic bag that increases the tensile strength by stacking inner and outer layers in different directions. The apparatus has a housing with an outlet, an extrusion mold inside, and a rotatable molding component. The extrusion mold has an outer part that extrudes the outer layer along the bag length. The inner part extrudes the inner layer rotated transverse to the outer layer. The rotatable component stacks the layers as they exit the mold. This creates a bag where the inner layer is transverse to the outer layer, preventing longitudinal tears when force is applied. The stacked layers have higher strength in both directions.

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A new extrusion process for making packaging boxes that allows complex shapes with curved surfaces, without the limitations and high costs of molding techniques like injection molding or stamping. The process involves extruding plasticized material, vacuum shaping it, cooling, pulling, and cutting to create the final box shape. The extruded material contains additives like calcium carbonate, wood flour, coupling agent, talc, and graphite flame retardant. This allows shaping the plastic into intricate forms during extrusion, followed by further shaping, cooling, pulling, and cutting steps to create the finished box.

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Three-dimensional molding method for resin packaging materials like pouches that allows hot filling without deformation. The method involves heating the packaging material below its Vicat softening temperature, compressing it at room temperature, and forming a 3D molded portion with overhangs. This prevents shrinking during hot filling. The compression molding is done below the Vicat softening temperature to avoid excessive thinning. The 3D molded portion has a thickness at least 50% of the original film thickness.

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Extruder and molding assembly that reduces strain orientation in molded parts without post-molding operations. The assembly has an extruder upstream of a mold with a separate pressurization member connected. The extruder fills most of the mold at low pressure, then the pressurization member finishes filling. This prevents high-pressure injection molding that can cause strain orientation. The isolation mechanism seals the extruder from the mold. The low-pressure extrusion fills most, then high-pressure final filling completes.

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A method for manufacturing aseptic packaging containers using injection molding to join the neck and body of the container. The method involves placing a packaging laminate sleeve with an inner thermoplastic layer between two mold tools. The mold tools are opened to inject melted material into the cavity. The mold tools are then closed and compressed to fuse the melted thermoplastic between the neck, shoulder, and laminate. This joins the neck and body of the container. The excess melt in the cavity is compressed out. The mold tools are then opened to remove the finished container. The method allows aseptic packaging with a single injection step instead of multiple steps like sealing and molding.

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Integrated thermoforming and extrusion machine for reducing material, time, and energy consumption compared to separate extrusion and thermoforming processes. The machine has an extruder, calender, cutting units, heating oven, forming station, and secondary cutting unit. After extruding the plastic sheet, it goes directly into thermoforming without cooling or cutting steps. The sheet is heated lower in the forming station since it already has some heat from extrusion. This avoids waste from edge thickening and cooling, and reduces time and energy by combining the processes.

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Biodegradable packaging material made by extruding biodegradable polymer blends onto fiber substrates. The blends contain high melt index polylactide (PLA) with a melt index over 35 g/10 minutes, along with biodegradable polymers like polybutylene succinate (PBS) or derivatives. This improves extrudability, adhesion, and heat sealability compared to using only low melt index PLA. The blends can be used as outer heat seal layers or inner adhesive layers in multilayer coatings on fiber substrates like paper or board. The biodegradable packaging material can be used for containers like cups, trays, and cartons.

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