SITUATION OVERVIEW

In today’s highly competitive retail environment, producers must deliver cost-effective, attractive, durable packaging to meet continuously changing consumer and market demands. A Husky customer that is a leading producer of dairy and deli foods, set an ambitious goal to increase productivity, boost profitability and reduce energy consumption – without compromising the premium quality of their products and containers, which typically feature in-mold label (IML) graphics.

HUSKY SOLUTION

Husky’s solution was its HyperSync™ high-performance packaging machine, which is designed to produce high-quality thinwall food and industrial packaging, among other applications, with superior levels of productivity, reliability, and energy efficiency.

The HyperSync’s high performance clamp, featuring unique Reflex™ platens, provided uniform clamp force distribution, enabling this producer to reduce cycle time, part weights and costs, and improve part quality and extend mold life. The high repeatability of the moving platen positioning also decreased scrap rate by ensuring consistent, accurate IML label placement. Its high-performance injection units, meanwhile, created a wider process window, with fast injection and recovery, increasing part quality, lightweighting, and operational flexibility.

RESULTS

Overall, the solution has resulted in several significant, ongoing improvements for the customer, including:

• A 35% reduction in energy consumption
• A decreased scrap rate
• Annual savings of $30,000
• Increased mold longevity and profitability

What Are IML Graphics?

IML graphics feature a pre-printed film or label that is applied to a container before injection molding. The film or label is then fused with the plastic during the molding process, resulting in a vibrant, high-quality, and long-lasting graphic that won’t scratch or fade. This process is widely used for consumer goods packaging and has been shown to increase the shelf life of products while enhancing visual appeal.

WHY CHOOSE A HYPERSYNC INJECTION MOLDING MACHINE?

HyperSync machines are designed to produce thinwall food and industrial packaging, specialty closures, and medical applications, with superior levels of productivity, reliability, and energy efficiency.

HyperSync machines feature precise synchronization of mold and machine processes, advanced melt flow control, a high-performing clamping unit, and Husky’s distinctive three-platen clamping unit, enabling extremely fast cycle times.

The high performance of HyperSync machines combines with high energy efficiency and is enabled by the latest Husky technologies. HyperSync’s electric mold stroke provides high acceleration rates for fast clamp movements, while providing significant energy savings. A built-in power management system with a compact, yet high performing Speed Variable Pump (SVP), provides power on demand enabling the reduction of spent energy.

Superior tonnage distribution via Reflex platens enables the production of high-quality parts with reduced clamping force, minimizing mold wear and extending the lifetime of tools. The systems also provide flexible interface options, proactive monitoring, intelligent networking, and intuitive controls, making them easier to operate.

To meet growing demands for performance flexibility, Husky offers HyperSync machines from 225 to 600 metric tons with a broad selection of injection units. Longer versions of the clamping unit are available for large shut-height tools.

NEXT STEPS

Speak with a Husky packaging expert to learn about how our latest technologies can address your packaging needs.