Thin Wall Container Mould
Mold Base Material: P20
Runner: Needle Valve Hot Runner
Characteristic: Separate Rice, Food and Soup
zhenke mould: your thin wall container mould expert
Advanced Processing Equipment
Zhenke Mold currently has more than 20 sets of various mold steel processing equipment such as CNC machine tools. Mold assembly machines can replace manual assembly of large molds, thereby improving mold quality.
Strict Quality Inspection
We use 7 injection molding machines of various sizes to conduct mold trials to check whether the mold is running well. We will be responsible for any quality issues.
Wide Range of Services
Our company has more than five years of experience in mold design and production. Since its birth, it has provided products and services to more than 30 countries and regions around the world and has more than 100 partners.
introduction to thin wall container mould
Thin wall container mould is widely used in takeout industry. The 8 compartment container mould products we designed and manufactured for customers can pack takeout meals better and more conveniently, and separate soups, vegetables, rice and other meals into different compartments. Keep dishes clean and tidy to prevent food odor. We are professional and experienced thin wall container mould makers.
Benefits of Using Thin Wall Molding
Higher precision
Thin-wall injection molding is able to produce thin-walled, lightweight plastic packaging boxes while maintaining the required strength and durability, providing higher precision manufacturing.
Faster production speed
Due to the use of dedicated machines and molds, thin-wall injection molding can achieve faster production cycles and higher productivity, manufacturing more plastic parts such as packaging boxes in a shorter time, thereby reducing overall production costs.
Environmental advantages
Thin-wall injection molding reduces energy and material consumption, helping to reduce environmental impact. Some of the thermoplastic materials used are recyclable or have used recycled materials, supporting long-term sustainable development.
Applications of Thin Wall Molding in Food Packaging
Thin wall molding is a highly efficient manufacturing process commonly used in the production of various types of food packaging. This technique is particularly suitable for products that require lightweight, durable, and cost-effective containers. Below are the key applications of thin wall molding in food packaging:
1. Lunch Boxes
Thin wall molding is used to produce lunch boxes made of lightweight, durable plastic, ideal for packaging meals. These lunch boxes must be strong enough to hold food securely but light enough for easy handling and transportation.
2. Sauce Cups
Thin wall molding is ideal for creating small, disposable sauce cups used for condiments like ketchup, mustard, or salad dressing. These small containers need to be lightweight, leak-resistant, and food-safe.
3. Ice Cream Containers
Thin wall molding is commonly used for producing ice cream tubs, cones, and other packaging types for frozen desserts. The thin walls help reduce the amount of plastic used while maintaining the necessary strength to hold the frozen product.
4. Plastic Jars
Thin wall molding is used to create plastic jars for packaging products like jams, sauces, dry foods, and spices. These jars require precise wall thickness to balance durability with lightness and cost-effectiveness.
5. Plastic Buckets
Thin wall molding is used to produce plastic buckets for larger food products, such as ice cream, yogurt, or bulk snacks. These buckets need to be durable enough to hold large quantities of food while being lightweight for easy handling and transportation.
6. Tea Milk Cups
Thin wall molding is used to manufacture disposable tea and milk cups, commonly used for beverages like bubble tea or milk tea. These cups must be sturdy enough to hold liquid and food ingredients while maintaining a lightweight and cost-effective structure.
We can customize various food container molds and use advanced thin-wall injection molding technology to help you improve your production efficiency.
Thin Wall Injection Molding technology
Thin wall injection molding is a specialized manufacturing process that produces parts with a wall thickness between 0.5mm and 1mm, and typically requires a volumetric flow length to wall thickness ratio greater than 75. This process is commonly used for creating lightweight, high-performance parts, especially in industries that demand high precision and efficiency, such as automotive, electronics, and packaging.
Key Considerations for Running Thin Wall Injection Molding
High Fill Pressures:
Thin wall molding requires significantly higher fill pressures to push the molten material into the mold cavity within very short cycle times. For engineering resins, the required fill pressures can range from 15,000 to 35,000 psi (100 to 240 MPa). These pressures are necessary due to the rapid heat dissipation of thinner wall sections during injection, which affects the flow behavior of the material.
Short Fill Times:
The fill time in thin wall molding is typically very short-often as low as 0.75 seconds. This is critical for achieving the desired part quality and to ensure the material flows properly into the mold before it begins to cool and solidify.
Mold Equipment Requirements: Due to the high fill pressures and rapid cycle times, mold equipment must be designed to withstand these extreme conditions:
- High-Torque Pumps & Accumulators: These are necessary for providing the required injection pressure and clamping force efficiently. The pumps should be capable of delivering consistent, high-pressure injection with minimal fluctuation.
- Clamp Force: For injection pressures around 30,000 psi (200 MPa), the clamp force needs to be substantial. Typically, a clamp force of 4 to 6 tons per square inch is required to prevent mold deflection and ensure consistent cavity filling.
- Precision Sensors: To control the high-speed hydraulic systems and ensure consistent pressure and flow throughout the process, high-precision sensors must be used to monitor and regulate the injection process.
- Thick Platens: The injection molding machine must have robust platens that are thick enough to minimize any deflection during high-pressure injection. The deflection should be kept to a minimum, typically as small as 0.0005 inches (0.013mm), to ensure accurate molding and part quality.
Smaller Shot Size & Barrel Capacity:
Thin wall molding typically uses smaller injection barrels, limiting the shot capacity to around 40-70% of the total barrel volume. This is done to ensure a more efficient and controlled injection process, especially for high-precision thin-walled parts that require exact material flow and temperature control.
Products Description
1. Demand Analysis and Material Selection
- Product Specification Determination: First, we will determine the design requirements of thin-walled containers with customers, including the size, shape, wall thickness, and function of the container.
- Material Selection: Select suitable engineering plastics, such as polypropylene (PP), polyethylene (PE), polystyrene (PS), etc., considering their fluidity, impact resistance, transparency, etc.
2. Design of various mold components
- Product Design Review: Our design team has rich experience in designing thin-walled container molds. During the design, they will analyze the structure of thin-walled containers and check whether there are possible molding defects (such as burning, shrinkage, warping, etc.).
- Main Runner and Divider Runner: Design the main runner (usually a runner with a larger diameter) and the diverter runner (a small runner entering each mold cavity). When designing the runner, we try to keep it short and wide to reduce the material flow resistance and ensure rapid and uniform filling.
- Gate Design: According to the product design requirements, select the appropriate gate type (such as point gate, ring gate, etc.) to ensure that the molten material can be evenly distributed throughout the mold cavity to avoid uneven flow.
- Cooling system design: The cooling circuit in the mold needs to be evenly distributed and close to the thin-walled area to ensure uniform cooling of the entire mold and prevent local overheating or overcooling.
- Exhaust design: Thin-walled molds are prone to gas accumulation. Our mold designs all have good exhaust designs to avoid bubbles or burnt defects.
3. Mold material selection
- High wear-resistant materials: We use high-quality steel including P20, H13, S136, etc.
- Surface treatment: In order to improve the durability of the mold, we usually need to perform surface treatment on the mold, such as chrome plating or nitriding, to increase its wear resistance and corrosion resistance.
4. Mold processing
Our mold processing usually requires high-precision processing using CNC (CNC machine tools), which can ensure the precise size and shape of each component of the mold. For some small mold details, especially complex structures such as cooling channels and runners, EDM is often used to improve processing accuracy.
5. Mold assembly and debugging
After all parts are processed, we will assemble the various parts of the mold to ensure that the gates, runners, cooling systems and other parts work in coordination.
6. Injection molding trial and optimization
Install the mold on the injection molding machine for preliminary debugging, perform trial, observe the molding results, and check whether there are any undesirable phenomena, such as incomplete mold filling, bubbles, shrinkage, deformation, etc.
Adjust the mold design according to the trial results, especially the cooling system, runner, gate and exhaust design. If it is found that some areas of the thin-walled container are poorly molded, it may be necessary to adjust the mold or injection molding process.
Why thin-wall mould get popular recently in food industry?
● Plastic thin-wall mold is widely used in the production of plastic containers and packaging. Its features are diverse and beneficial for industrial manufacturing.
● Plastic thin-wall molds are highly beneficial to the injection molding process, thanks to their precision, durability, speed, and ease of maintenance. These characteristics not only result in high-quality parts, but also increase efficiency, reduce waste, and boost profitability for manufacturers.
● Plastic thin-wall molds are designed for easy maintenance and repair, which prolongs their lifespan and reduces downtime. Regular maintenance and repair of these molds can prevent issues such as wear and tear, corrosion, and warping, which can cause defects in molded parts.
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