Ceramicx Discusses Thermoforming In Packaging

Frank Wilson, founder of Ceramicx, discusses the thermoforming work involved in plastic-packaging manufacturing. Plastics-packaging thermoforming-production systems - particularly high-speed packaging lines for food and beverage applications - all have their areas of opportunity and weakness. It is easily forgotten that the thermal systems installed as part of the thermoforming process are the engine of production. Without maintenance and sufficient analysis, production output and quality will suffer.

Infrared heaters, ceramic heaters, quartz heaters and ceramic elements are all based on a specific technology. The more understanding gained of infrared science, the better production will be. Plastics processors and packaging users often point to the heating system as a possible cause of packaging deformation and quality failure. However, as a general rule, heat systems are very rarely the cause of production problems. Instead, the complexity of the packaging part design, its dimensions, the depth of the thermoforming 'draw' and the characteristics of the material composition are the prime factors that must be calculated and overcome in order to make quality product.

The essence of infrared heating involves three factors - absorption, transmission and radiation. A good infrared heating system is one in which incoming electrical wattage is converted into infrared output more quickly and efficiently. In thermoforming production a number of infrared ceramic heaters are generally mounted on reflectors, which are then arrayed upon a platen that is part of the production line. The performance of the background reflectors, their material composition and the performance of the platen in general are all vital factors in directing the infrared heating to the plastic.

But too often, packaging processors of thermoforming machines end up fighting the demands and design of their machine in order to perform efficient heat work. For example, stainless steel is not an adequate material for use in infrared reflection work. It will absorb a high percentage of the emitted energy and will, over time, cause burnout of the electrical wiring behind the reflector and start to discolour from 120C. Polished aluminium is, in most cases, the best reflector for ceramic infrared heating, but at more than 500C it also will start to fail.

The business of thermoforming thin and clear plastic sheet requires the installation of passive ceramic tiles in the base of the platen in order to reflect back the heat. In many cases, as a platen system starts to discolour and degrade in operation, the reflectivity will be compromised and the machine operator will be involved in a vicious circle of increasing the temperature in order to achieve the same performance. A 30-40 per cent improvement in operational efficiency of most packaging thermoforming systems can be achieved through reviewing and renewing the infrared heating platen.

One solution is to mount a thermocouple on the existing reflector system. When this starts to rise, the user should be alerted to take action. This issue will continue to bear on the packaging industry as cost-down and higher-quality demands continue. Ceramicx believes that the consciousness of the future packaging industries will no longer tolerate substandard parts and poor thermoforming design. The company is therefore kite-marking and badging all of its heaters and elements as guarantees of quality in packaging production. Ceramicx intends to badge 75 per cent of its output before the K 2010 plastics exhibition in Dusseldorf.

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