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Vacuum Forming packaging is a general term for plastic products produced by Vacuum Forming technology and packaged with corresponding equipment.
Introduction
Vacuum Forming products mainly use high-quality PVC, PET, PP, PS, GAG, flocking and other plastic materials to produce high-grade and various specifications of electronic Vacuum Forming packaging, stationery Vacuum Forming packaging, toy Vacuum Forming packaging, hardware Vacuum Forming packaging, food Vacuum Forming packaging, daily chemical gifts and crafts Vacuum Forming packaging. Vacuum Forming packaging is of high quality, low price, and can beautify your products, attracting more customers.
Advantages
1. Vacuum Forming packaging can improve the price and image of the product itself, and at the same time, it also has the function of shaping and spreading, which has a significant impact on the brand image and popularity of the enterprise.
2. Vacuum Forming packaging also aims to display and protect products. Most of the packaged products are small commodities, which can be placed or hung on the shelves of supermarkets, so that your products can be perfectly displayed in front of customers and promote product sales.
Third, Vacuum Forming packaging is used for separation, shockproof and foiling. The products packaged are mostly electronics, IT, industrial parts, toys, stationery, food, crafts and cosmetics, etc. It can package multiple and small products to make the products more beautiful as a whole.
Products
Products mainly include: Vacuum Forming, tray, Vacuum Forming box, synonyms include: vacuum cover, Vacuum Forming, etc.
Equipment
Vacuum Forming packaging equipment mainly includes: Vacuum Forming packaging machine, Vacuum Forming forming machine, punching machine, sealing machine, high frequency machine, folding machine.
Products
The packaging products formed by encapsulation can be divided into: card insertion, suction card, double Vacuum Forming, half Vacuum Forming, folded Vacuum Forming, trifolded Vacuum Forming, etc.
Raw Materials
The raw materials of Vacuum Forming packaging mainly include: PVC, PS, PP, PET, PETG and flocking, antistatic, conductive and other materials.
1: Mold making and processing: According to the requirements or sample specifications, first make the Vacuum Forming mold. Under normal conditions, gypsum is used to make Vacuum Forming packaging molds, but there are also products with wood carvings and metal carvings as molds. After the gypsum mold is made, let it dry naturally or dry it. Then, according to the specific conditions of the product surface, use a 1-2 mm drill to drill many small holes in the concave areas that do not affect the appearance of the product packaging. If it is a product such as a packaging box, you have to drill some small holes around it so that the air can be extracted during the Vacuum Forming production. After the mold is drilled, the gypsum mold must be hardened. The hardening method is to soak it in a saturated solution of concentrated alum and then dry it.
2: After the mold is completely dried, put the mold on the upper iron plate of the vacuum chamber, and then according to the size of the mold, load the plastic sheet into the appropriate size, and then put the sheet into the heated wooden cabinet to make it completely fixed, and then put the wooden cabinet and the plastic sheet in a constant temperature furnace for softening.
3: Place the softened plastic sheet together with the wooden cabinet in a vacuum chamber, turn on the suction switch, and suck out the air in the vacuum chamber. After the plastic sheet cools down, you will get a concave package or process mold that is the same as the mold.
4: Vacuum Forming packaging finishing: The products produced are trimmed to make them finished products, and then they can be sold after packaging.
Unit price of Vacuum Forming = product material cost + energy consumption + labor and transportation + profit
Energy consumption: Vacuum Forming is processed through heat, and the electricity consumption is relatively large compared to other industries, which is roughly 8% of the product material cost. Labor: Vacuum Forming is mainly produced by machines, with less labor, which is roughly 10% of the product material cost. Transportation: It depends on the distance between the customer and the factory. Profit: The net profit of the Vacuum Forming factory is generally very low, 12%-20%, depending on the payment period, and 14% for 30 days settlement. Material cost: The calculation of product material cost is relatively complicated. Before calculation, we must first clarify the following data:
Raw material price: According to the purpose of the product, determine what material and grade of material to use, and find the lowest price supplier of this material. Film thickness: Predict how thick the film should be made of for the product, which should be determined according to the thickness and shape of each part of the molding. Layout quantity: According to the product's overall size and shape, calculate how many molds can be arranged in one version. Too dense arrangement will reduce product quality, and too sparse arrangement will increase material loss and increase costs. Material loss rate: The main factors are product shape, product quantity, and the degree of fit between the overall size and the chassis of the Vacuum Forming machine. The squarer the shape and the greater the output, the smaller the loss rate
Material cost calculation formula
Product material cost = 1 ton of raw material price / 1 ton of raw material finished product quantity
1 ton of raw material finished product quantity = 1 ton of raw material length / (Vacuum Forming template length + 4cm to 15cm stretch edge) X layout quantity X (100% - material loss rate) 1 ton of raw material length = 1 ton / material density / film thickness / width (Vacuum Forming chassis width) Among them, material density (PVC is 1.36T/M3), Vacuum Forming chassis width (0.51-1.20M), template length and other four parameters are estimated based on professional experience. Material introduction 1. PVC sheet has high toughness and is not easy to burn. It will produce chlorine when burning, which has a certain impact on the environment. PVC is easy to heat seal and can be sealed with a sealing machine and high-frequency edge sealing. It is the main raw material for the production of transparent Vacuum Forming products. PVC sheet is a widely used and popular material. PVC film can be divided into two types: environmentally friendly and non-environmentally friendly. It can be made into transparent, colorful, anti-static, gold-plated, flocking and other Vacuum Forming packaging products. Its main features are high transparency, good surface gloss, few crystal points, small water marks, wide application, strong impact resistance, and easy to form. The products are widely used in the outer packaging of toys, food, electronic products, medicine, electrical appliances, gifts, cosmetics, stationery and other products.
Second, PS hard sheet has low density, poor toughness, easy to burn, and produces styrene gas (a harmful gas) when burned, so it is generally used to produce various industrial Vacuum Forming trays. PS sheet is a new type of environmentally friendly packaging material developed in recent years. With its excellent thermoforming performance, good environmental performance and hygienic performance, it is widely used in medicine, food, toys, and electronics.
Third, PET hard sheet has good toughness and is a new material developed in recent years. With its excellent toughness, high strength, high transparency, and recyclable and reusable, easy to burn, no harmful gas is produced when burned, it is an environmentally friendly material and gradually replaces PVC, but the price is high. Suitable for high-end Vacuum Forming products. Vacuum Forming shells in European and American countries generally require PET materials, but its high melting point brings great difficulties to high-frequency packaging.
Fourth, PETG material is to solve the problem of high melting point of PET material. People compound a layer of PVC film on the surface of PET and name it PETG, but the price is higher. It is mainly used for electronics, food, toys, color box windows, collars, shoe packaging, etc. [span] Its advantages are as follows:
1. It has excellent transparency and smoothness, and good display effect.
2. It has excellent surface decoration performance, can be printed without surface treatment, easy to press patterns, and easy to metalize (vacuum metallization layer)
3. It has good mechanical strength.
4. It has good barrier properties to oxygen and water vapor.
5. It has good chemical resistance and can withstand the erosion of various chemical substances.
6. Non-toxic, reliable hygienic performance, can be used for packaging food, medicine and medical equipment, and can be sterilized by Y-rays.
7. Good adaptability to environmental protection, can be economically and conveniently recycled; when its waste is incinerated, no harmful substances harmful to the environment are produced. This type of sheet is considered to be an ideal packaging material that meets the (ROSH) environmental protection requirements.
V. PP sheet is made of polypropylene resin as the main raw material, adding various process masterbatches, toughening agents and brightening agents, and is made through mixing, plasticizing extrusion, three-roll calendering, cooling, traction and winding. PP sheet has the characteristics of non-toxicity, tastelessness, hygiene, high mechanical strength and good barrier properties, and can be used for packaging in industry, agriculture, fruit and other industries. The tray made of PP anti-slip sheet has a smooth and beautiful surface and is very popular with users. PP sheet is also suitable for the packaging of highly cold-resistant frozen foods, such as ice cream boxes, dumpling boxes, and glutinous rice balls boxes.
PP Vacuum Forming has the following advantages: environmental protection, beautiful appearance, screen printing, offset printing, hot stamping, high temperature resistance, low temperature resistance, high transparency, bending resistance, products meet food testing standards (optional), microwaveable.
PP disadvantages: low dimensional accuracy, insufficient rigidity, poor weather resistance, easy to produce "copper damage", it has post-shrinkage phenomenon, after demoulding, easy to age, become brittle, easy to deform.
1) Good protection.
2) Transparent and intuitive.
3) Easy to use.
4) Lightweight.
Vacuum Forming packaging molds generally include plaster molds, electroplated copper molds and aluminum molds
Plaster molds: plaster is carved in a semi-wet state, and then dried to form a mold. Plaster molds are low in cost and easy to modify, but the precision of plaster molds is not high enough, the surface is not smooth, and it is fragile and not durable. Therefore, it is often used to make molds for electroplated copper molds or some Vacuum Forming molds with low requirements and small batch production.
Aluminum mold: It is made of aluminum ingots through machinery (lathes, milling machines, CNC, etc.). Aluminum molds have high precision, smooth surface and are durable, but the price is very expensive. Aluminum molds are generally used in Vacuum Forming products with high precision requirements that copper molds cannot achieve.
Electroplated copper mold: After making a sample with a gypsum mold, a layer of copper shell is electroplated to form an electroplated copper mold. The cost is relatively high for a gypsum mold, but it is much cheaper than an aluminum mold. Due to its advantages of smooth and durable surface and low cost, the electroplated copper mold is the most commonly used Vacuum Forming mold.
Vacuum Forming: A plastic processing technology, the main principle is to heat and soften the flat plastic hard sheet, and then use vacuum to absorb it on the mold surface, and then cool it to form. It is widely used in plastic packaging, lighting, advertising, decoration and other industries.
Vacuum Forming packaging: A general term for plastic products produced by Vacuum Forming technology and encapsulated with corresponding equipment. Vacuum Forming packaging products mainly include: Vacuum Forming, tray, Vacuum Forming box, and synonyms include: vacuum cover, Vacuum Forming, etc. Vacuum Forming packaging equipment mainly includes: Vacuum Forming forming machine, punching machine, sealing machine, high frequency machine, folding machine.
Vacuum Forming: The transparent plastic hard sheet is made into a transparent plastic with a specific convex shape by using the Vacuum Forming process, and covered on the surface of the product to protect and beautify the product. Also known as Vacuum Forming, vacuum cover
Tray: Also called plastic inner tray, the plastic hard sheet is made into a plastic with a specific groove by using the Vacuum Forming process, and the product is placed in the groove to protect and beautify the product.
Flocking inner tray: It is a Vacuum Forming tray made of special materials. A layer of velvet material is glued to the surface of ordinary plastic hard sheets, so that the surface of the tray has a velvety feel, which is used to improve the grade of the packaged products.
Antistatic tray: It is a Vacuum Forming tray made of special materials. The surface resistance of the material is less than 10 to the 11th power ohm. It is mainly used for Vacuum Forming trays for electronic and IT products.
Vacuum Forming mold: The mold used for Vacuum Forming production has the lowest cost of plaster mold, followed by electroplated copper mold, and the most expensive is aluminum mold. The mold is drilled with small holes for vacuum adsorption of heated hard sheets to form Vacuum Forming products.
Vacuum Forming molding: It is what we often call Vacuum Forming. The Vacuum Forming molding machine is used to adsorb the heated and softened plastic hard sheet on the surface of the mold. After cooling, a concave and convex shape of plastic is formed.
Vacuum Forming cutting: After the plastic products are Vacuum Forming-formed, the large sheets are cut into individual products by a punching machine.
Folding: There is a kind of Vacuum Forming packaging called card insertion packaging. The three sides of the Vacuum Forming shell need to be folded to the back with a folding machine so that the paper card can be inserted into the folding edge in the next packaging process to form a card insertion packaging.
Heat sealing: It is a Vacuum Forming packaging process. The paper card with Vacuum Forming oil on the surface is heat-sealed with the Vacuum Forming shell by a sealing machine to form a Vacuum Forming card packaging.
High-frequency sealing: It is a Vacuum Forming packaging process. A high-frequency machine is used to generate high frequency to bond the Vacuum Forming shells together to form a double Vacuum Forming packaging.
Ultrasonic sealing: It is a Vacuum Forming packaging process. An ultrasonic machine is used to generate ultrasonic waves to bond the Vacuum Forming shells together to form a double Vacuum Forming packaging. Unlike high-frequency sealing, ultrasonic waves can not only seal PVC and PETG materials, but also PET materials, and there is no electromagnetic damage to the packaged products, which is particularly suitable for the packaging of electronic products; the disadvantage is that ultrasonic edge sealing can only be in the form of interval points, and generally only one straight edge is sealed each time.
What is the crystal point? How to solve the problem?
The crystal point is a point on the Vacuum Forming packaging material, which will seriously affect the appearance of the Vacuum Forming packaging product. The quality problem comes from the sheet supplier. The reason for this is that when the sheet is produced, there are sundries mixed in the material, which will cause this kind of quality condition. The solution is to check the sheet before producing the Vacuum Forming packaging product.
What is the cause of uneven thickness? How to solve such a problem?
The most common points of uneven thickness are shelves, sheets, temperature, etc. When the shelves are pressed on the Vacuum Forming packaging product, the position adjustment is very critical. If there is a misalignment or unreasonable placement, uneven thickness will occur. What is related to the sheet is that the thickness of the sheet is not adjusted properly during the production process, so it will cause such quality problems. The temperature adjustment is also directly related, and the corresponding temperature should be adjusted according to different molds and different materials, otherwise unevenness will occur. The solution is to pay attention to the position adjustment of the shelf, the negotiation of the supplier of the sheet material, and the temperature adjustment to the suitability of the sheet material and the mold.
What is the pull line? How is it caused? How to solve it?
The pull line is a protruding line on the edge of the product, which seriously affects the appearance of the packaging. The reason for the generation is that such a situation is related to the structural manufacturing of the Vacuum Forming mold, the controlled operation of the Vacuum Forming molding machine, the temperature adjustment, and the shelf are closely related. The solution is the quality control of the mold, the adjustment of the machine and temperature parameters, and the extrusion of the shelf.
What are water ripples and bubbles? How is it caused? How to solve it?
Water ripples and bubbles are watermarks and bubble points on the surface of the material. Such Vacuum Forming products will directly affect the appearance of the packaged items and reduce the appearance of the packaged items. The cause of water ripples is the relationship between the sheet material supplier and the sheet material in the production process. The water ripples are related to the speed of producing the film. The reason for bubbles is that the temperature is too high during the production of the sheet, or the mixed production of the sheet or the air infiltration during the production of the sheet. The material with bubbles will cause the Vacuum Forming packaging products to be perforated and deformed, becoming defective products. The solution is to observe the quality of the sheet when the material is purchased or before production before it can be put into storage or production.
What is a scratch? How does this quality problem occur? How to solve it?
Scratches are scratch marks on the surface of Vacuum Forming products after they are produced. It is also a frequent problem in quality. The reason for the occurrence is that in the production process, there are many manual processes, which are prone to collision and friction. The operation method of the punching machine personnel and the packaging personnel is the most critical link. The solution is to handle the product with care, keep the workbench clean and hygienic, and the staff wear gloves and other related matters, which can also effectively prevent scratches. There are many manual processes for Vacuum Forming packaging products, so close attention must be paid to each link to avoid the production of defective products.
First, in 2004, the total output value of China's packaging industry is expected to reach more than 300 billion yuan, with an annual growth rate of about 7%, of which paper packaging products will reach 19 million tons, plastic packaging products are expected to reach 5.04 million tons, metal packaging products are expected to reach 2.88 million tons, glass packaging products are expected to reach 10.5 million tons, and packaging machinery will reach 670,000 sets.
From 2006 to 2010, the total output value of the packaging industry is expected to reach 450 billion yuan, maintaining an average annual growth rate of 7%.
From 2011 to 2015, the total output value of the packaging industry can reach 600 billion yuan, with an average annual growth rate of 6%. By 2015, paper packaging products will reach 36 million tons, plastic packaging products 9.46 million tons, metal packaging products 4.91 million tons, glass packaging products 15.5 million tons, and packaging machinery 1.2 million sets.
The packaging industry, combined with industrial structure adjustment, will be more reflected in the reduction of product consumption, structural optimization, variety improvement, quality improvement and enhanced competitiveness. Products that meet consumption upgrades, scientific and technological progress and sustainable development will accelerate growth. China will pay enough attention to the import of medium and high-end packaging raw and auxiliary materials and high-end machinery and equipment.
Fifth, by 2020, China's packaging industry will meet the needs of building a well-off society in an all-round way and build a new Chinese packaging industry with high technological content, good economic benefits, low resource consumption, less environmental pollution, and full utilization of talent resources.
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