AIPAK Thermoforming Machine

1.What is a thermoforming machine?

AIPAK thermoforming machine

Thermoforming machines are extensively employed for the processing of plastic. Thermoforming machines simply put are instruments that are used to mold or cast various kinds of materials like plastic and polymers into a usable product. For transforming materials into molds, generally, these materials are heated to a high temperature by thermoforms.

Different packaging products are formed by thermoforming machines. Thermoforming machines are widely employed in the packaging industry to extend the shelf life of products and their safe transport.

2.What are the various features of thermoforming machines?

• Thermoforming machines are durable and are made of stainless-steel material.
• These machines have complied with CE, EC, and GMP regulations.
• These machines are multi-purpose and are able to process a large number of materials like PVC, PET, acrylic, PP.
• Thermoforming machines are equipped with a user-friendly touch screen HMI display for customized machine operation.
• These machines have low maintenance and cleaning.
• Thermoforms have PID automatic systems for temperature control.
• Thermoforming machines have camera control drive technology for reproducibility.

3.What are the basic types of thermoforming machines?

Thermoforming machines are classified into different kinds based on

• Level of Automation
• Technique
• Filling

Classification on the Level of Automation

There are three kinds of thermoforming machines based on the level of automation. These are:

Ⅰ.Manual Thermoforming

In this type of thermoforming, all the functions are carried out by the operator. The first material sheet is placed inside the feeder by the trained person. Then the heating temperature of the oven is set mechanically to a specific product kind after every batch run. Molding in manual thermoforming is also performed by hand.

Ⅱ.Semi-Automatic Thermoforming Machine

Semi-automatic thermoforming machines are usually suited for small to medium-sized packaging. Some functionality like feeding in these kinds of machines is performed by working personnel while some processes like molding are automatically executed.

Ⅲ.Automatic Thermoforming Machine

In automatic thermoforming machines, every process from feeding to trimming is automatically carried out. There is no need for an operator to operate these machines. These machines are designed for large-sized productions and are equipped with touch screens on which all the machines’ parameters are set for running.

Classification on the Basis of Technique

Ⅰ.Vacuum Thermoforming

It is a simplified type of thermoforming where plastic is heated, stretch onto the mold surface, and then vacuum is used to force the plastic sheet in the molding tray. Vacuum thermoforming is used to convert plastic into a permanent item like turnpike signs and protective covers. Vacuum thermoforming employs one mold either male or female.

Ⅱ.Pressure Thermoforming Machine

The pressure thermoforming machine employs a heating system to increase the temperature of a sheet, use a vacuum for removing air, and force the sheet to stretch against the mold. Also, die tooling is used to apply pressure for maintaining the final shape of the thermoformed plastic.

This machine is used when deeper details in the forming are required.

Ⅲ.Blister Thermoforming Machine

This machine heats the forming film until it gets soft. Then this soft film is used to create a blister by the compressed air informing unit. Afterward, filling unit package the product like a tablet, capsule, batteries into the blister.

Classification on the Basis of Material Filling

Ⅰ.Thermoforming Liquid Filling Machine

This machine is used to fill and seal aseptic liquid inside tablets, capsules, pills, candies, syringes, and aluminum-plastic thermoformed containers like cups and bottles.

Ⅱ.Suppository Filling Thermoforming Machines

This machine fills and seals active ingredients inside a torpedo-shaped softgel. This machine makes drugs for rectal and urethral administration. The machine melts the base material and dissolves active ingredient inside the drug. Then this molten substance is poured inside the casting tray and then cooled. Suppository filling machines infuse the active ingredient inside the empty capsule.

4.What are the prime applications of thermoforming machines?

Thermoforming machines are very important in the processing of plastic materials for packaging. It is used in a wide variety of industries to produce various kinds of thermoplastics. Some important industries are given below:

Pharmaceutical and Medical Industry

Many pharmaceutical and medical items like injections, vials, and ampoules are packed in thermoplastic to keep them safe and prevent their breakage. This packaging is possible because of the thermoforming machines.

Thermoforming machines are also used for packaging MRI, X-rays, CT scan types of equipment, trays, bins, electronic items, etc.

Electronic Industry

Various kinds of blister trays and plastic shells are manufactured by the thermoforming machines for storing electronic items like nuts, cables, gadgets, and other portable devices like computer’s mouse and flash drives. These blister trays aid in the transport of these fragile items.

Food Industry

In the food industry, thermoforming machines have a special place as these machines form plastic bowl and container, in which foodstuff are a place for safe traveling and storage for a long time. These machines are employed in making noodle jars, coffee cups, and food packaging boxes.

Construction Industry

Construction and building items like machines casing, toolboxes, and equipment enclosures are formed by the thermoforming machines using polycarbonate materials.

Automotive Industry

Thermoforming machines are an integral part of the automotive industry and are employed to make dashboards, bumpers, air pipes, and door panels. These machines are also used to repair different automotive parts.

5.What are the different components of the thermoforming machine?

It is very important to know about the function of various components in thermoforming machines as this helps in fixing the problem in any of these parts. Some important parts are discussed below:

Heating System

Ceramic heating plates form the heating unit; these plates heat the plastic sheets when they go into the heating unit. These plates rapidly get heated and are used in various electric instruments. By these plates, molding is easily performed.

Material Feeding Unit

The feeding unit is used to load the plastic material to the conveyor. This unit starts the thermoforming process by feeding the sheet to other parts for molding.

Conveyor

The conveyor component takes plastic from the feeder and transports it to the heating unit. The conveyor part is the belt that is used for the movement of materials to different parts.

Forming Unit

Forming station has a molding tray on one side and a pressure box on the other side. The holes in mold and force from the pressure box are employed to create different plastic shapes.

Punching Unit

The function of this component is to perform the molding of plastic when it enters the molding unit. It is stretched onto the mold and the punching station punches the material so that it can have the desired shape.

Control Panel

These machines have a touch screen display that is used to operate the machine. All the parameters for running the machines are programmed on this display. You just have to see the machine in action without putting in much effort.

Cutting Station

The function of the cutting station is to further process like cutting the corners or trimming the product. When the containers are shaped in the molding system, then the edges of these containers are cut inside the cutting unit. For example, a plastic box is cut into two parts; one for holding the product and the other for covering it.

Collecting Bin

The final products after cutting and trimming are collected inside the collecting station. This bin is also used to amass the material that is wasted in thermoforming. This wasted material is reused unless it is not severely damaged.

A conveyor belt is used to transport the product to the collecting bin.

6.What is the working principle of a thermoforming machine?

It is important that you should understand how thermoforming machines work, as it will help you in solving problems that arise during the thermoforming process. The working steps of the thermoforming machine are described below:

Pre-heating

First, the material whether it is plastic or polymer is entered into the hopper also known as thermoformed. It simply inspects the type of material. Then the plastic sheet goes from hopper to heating terminal.

Heating

In the heating terminal, the heating oven provides the desired heat to the material. Heating is a very important step in thermoforming as it supplies the required temperature to transform plastic material into various shapes and forms. The heating temperature for polycarbonate is 180-190 °C.

Molding

The sheet goes to the molding unit where it is placed in the molding tray. In this step, compressed air or vacuum mold transforms the polymer sheet into the desired form. The polymer sheet contract upon losing heat and changes its form to match the shape of the molding tray.

Cooling

After molding the molded material enter the cooling unit. The product is cooled and hardened by the cooling fan.

Trimming

The cooled product then passed through the trimmer. In this unit, the molded material is given a suitable shape and cut into a preferred shape. After trimming, the product is passed into the collecting bin.

7.Five major advantages of thermoforming machine?

Thermoforming machines play a significant role in many industries. The five major advantages of the thermoforming machines are given below:

Production Efficiency

Manual labor for packaging items takes a lot of effort and time. Moreover, repeatedly performing one take get tiring and boring after a certain time period. But with the help of a thermoforming machine, you will get more packaging done in less time. This machine improves your production efficiency and increases the number of your products on the market.

Cost

Buying a thermoforming machine will benefit you and save you from paying a huge amount of money to your labor to compensate them for their long working hours. This machine will perform more of the work that was otherwise carried out by the working personnel thus saving your labor expenses.

Wastage of Material

By using thermoforming machines there is minimal wastage of expensive thermoforming material. This saves your money and also reduces the environmental impact.

Reproducibility

Thermoforming machines give consistent and reliable results. These machines form products of the same size and shape every time but it is not possible by doing work manually.

Ease of Operation

These machines are easy to handle and operate. Minimal training is required to operate these machines. Also, with a few adjustments, different products can be created by thermoforming machines.

8.What is the difference between thermoforming and cold forming machines?

Thermoforming and cold forming machines both mold the plastic sheets into boxes or containers. Below are some differences between both machines.

Heating Plates

Thermoforming machines involve the use of a heating units to transform plastic into various shapes. While cold forming machines do not have heating plates for molding. All the cold roll shapes are formed at room temperature.

Strength

Cold Forming machines form products that are more durable and have tensile strength while thermoforming machines apply heat to plastic that prevent them from hardening as a result these products do not have tensile strength.

Trimming

Thermoforming machines involve the process of trimming or cutting to sharpen the edges. There is no cutting or trimming in cold-forming machines. This also saves the loss of material which is impossible in thermoforming.

Uses

Thermoforming machines are used to make L-beams for construction while cold forming is used to make refrigerator parts and solar panels.

9.What are the maintenance tips for thermoforming machine?

Thermoforming machines have a long operational life lasting for decades if these machines have proper cleaning and maintenance schedule. Below are some maintenance tips for thermoforming machines.

Daily

• All the parts should be lubricated daily to avoid friction.
• Check the mold thickness mechanism daily to prevent slackness of the drive shaft.
• Check for the loose electric connection
• The heating system should be examined daily for hairline cracks.
• Remove the dust and debris from the exterior of thermoforming machine.

Weekly

• Check and lubricate air supply pneumatics on weekly basis.
• Check for the leakage in the pressure hose.
• Check air condition for moisture and dust.

Monthly

• Fasten the loose nuts in every station
• Check the working condition of every alarm sensor

10.How to troubleshoot a thermoforming process?

Problems are the part of a routine run of the thermoforming process. A few tips and suggestions are given below to counter these problems.

Ⅰ.Burned Packaging

Sometimes there are burned spots on the thermoforming sheets.

Reason

• The external surface of the sheet is very hot.

Solution

• Lower the heat and increase the heating duration
• Heat both surfaces of the material.

Ⅱ.Poor Detailing

There is incomplete forming and poor design on the thermoforming material.

Cause

• The temperature of the sheet is low
• There is not enough pressure

Solution

• Increase the heating time.
• Increase the temperature of heating oven
• Examine leaks in the pressure unit
• Inspect the molding leakage
• Inspect if vacuum holes are clogged

Ⅲ.Webbing or Bridging

Webbing or bridging occurs when there is unnecessary wrinkling in the sheeting.

Cause

• The pressure rate is high
• Poor design and layout
• Forming approach is not correct
• Sheet temperature is high
• Vacuum pressure is not enough

Solution

• Redesign the molding
• Space blocks should be added to take up excess space.
• Make necessary adjustments to correct forming method
• Lower the temperature
• Add more venting holes
• Check the leakage in the vacuum system

Ⅳ.Warpage

Sometimes thermoforming parts get twisted or deformed

Cause

• Little cooling time
• Molding external side temperature is hot
• Bad molding design
• Pressure is inadequate

Solution

• Increase cooling duration
• Check the water pumping system
• Improve the molding design
• Ensure air ports in molding systems are not clogged
• Check for leakage in air pipes

Ⅴ.Bubbles

Bubbles or blisters are seen on the surface of the thermoforming part.

Cause

• Excessive humidity
• Uneven distribution of heat
• Heating of material is rapid
• Temperature is too high

Solution

• Dry the sheet before heating
• Protect the thermoforming material from moisture
• Heat the material gradually to the forming temperature
• Check for overheating units in the oven
• Reduce the forming temperature

Ⅵ.Flow lines

Sometimes lines can be seen on the thermoformed part

Cause

• Loose chain drive cause chatter
• Melting of the resin blend
• Die marks of the backside of the part

Solution

• Process the material on the chain drive which is in good working condition
• Mix the resin blend more meticulously
• Process the material at the lower temperature

Ⅶ.Chill Mark

Sometimes chill mark a deformity or blemish is seen on the surface of thermoformed material.

Cause

• The molding temperature is very low. The material gets frozen when it encounters the molding.
• Incorrect forming technique
• The temperature of the sheet is very high
• Decreased plug temperature

Solution

• The temperature of the molding system should be high
• Use an appropriate forming technique
• Reduce the heating oven temperature
• Increase the plug temperature
• A plug should be covered with insulating material

11.Discuss some basic safety instructions while operating the thermoforming machine.

Following are the basic safety instructions that should be considered to prevent accidents while operating thermoforming machines.

• Use proper elevating devices for raising plastic and tools off the floor.
• Working staff should be trained fully to use and maintain thermoforming machines.
• Wear proper protective types of equipment like gloves, closed footwear, helmet while servicing and cleaning the thermoforming machines.

• Use barrier guards and interlocked gates to prevent the entry of unauthorized staff in machine working zone.
• While cleaning cutting knives use energy control procedures to prevent injury.
• Proper ventilation should be ensured to remove dust from the working area.
• Special care should be taken while opening oven doors to prevent burns from hot air.
• Do not operate thermoforming machines in wet or damp areas in order to prevent electric shocks.

12.Major consideration factors before investing on a thermoforming machine?

Today, there is a wide variety of thermoforming machines available on the market. It is difficult to select the right kind of thermoforming machine. Here, some factors are given that will help you in choosing the right match of thermoforming machines for your business.

Ⅰ.Production Size

First define the size of production, in which you are going to use the thermoforming machine. By doing this, it will become easier for you to select the appropriate kind of thermoforming machine. If you are interested in forming packages on large scale then choose automatic thermoforming machines.

But if you are running a pilot plant or have small-sized production then select either manual or semi-automatic thermoforming machine.

Ⅱ.Usability

You should select that thermoforming machine that is user-friendly. Choosing thermoforming machine which is equipped with a touch screen interface and can be operated with minimal ease will be advantageous for your production run.

Ⅲ.Installation Space

Select a thermoforming machine that is well-matched with your installation space. It will be difficult for you to install a large thermoforming machine in a small space. The small-sized machine is suited for small floor space.

Ⅳ.Thermoforming Material

Thermoforming machines can process different kinds of materials so it is important that you should select the machine that can process your packaging material like PVC, PET, PP, etc.

Ⅴ.Safety Aspects

It is of utmost importance that you should go for thermoforming machines that have all necessary safety compliance in order to prevent injuries and accident on the site of operation.

Ⅵ.Automation

If you require quick and efficient production, then choose an automatic thermoforming machine. It will also save your labor expenses. Manual and semi-automatic thermoforming machines are employed in medium-sized plants.

13.What are the future trends of thermoforming machine market?

Thermoforming machines are highly popular in various industries like textile, food, pharmaceutical, medical, personal care, electronics, aviation, and many other industries. With the growing population and increased urbanization, the demand for thermoforming machines has been on the raise.

The market value of the thermoforming machines in 2020 was about 894.2 million USD and is predicted to reach about 1225.8 million USD in 2026 with a CAGR of 4.6%.  The automatic thermoforming machine has the largest proportion of thermoforming machine market about 73% in 2019.

It has been estimated that thermoforming machines are mostly used about 28% in the food and beverage industry while the consumer products industry 22% of thermoforming machines.

The global report predicted that South Asia and America are the two leading regions in which thermoforming machines will be mostly used. While in Europe, Italy, Germany, and UK will be at the forefront of thermoforming machine market.

With the growth of e-commerce, more and more people will be ordering the thermoforming machine online; this will increase the need for thermoforming machines. So automatic thermoforming machines will be produced on large scale to satisfy increasing exigency for packaged goods.

Conclusion

A thermoforming machine is the advanced category of filling and sealing your products which is programmed for different products and various designs. AIPAK good quality thermoforming machine are especially designed for safe and convenient process. The entire machine structure is made up of stainless steel, gives you an ideal arrangement types for regular and irregular shapes (candies, capsules, tablets, cosmetics etc.). If you want more assistance. Don’t hesitate to contact us and get product quotation with excellent customer services right now.