Until now, anyone who wanted to give plastic packaging sophisticated surface properties such as transparency, matt effects or a non-slip texture had to go through many different processing steps. The US plastics specialist PolyOne has developed the „SmartBatch Frost Collection“, which achieves all of these effects in just one step.
This presents PolyOne a range of Colour and additive masterbatches for new and recycled PET plastics. This makes it possible to optimise the production processes for plastic packaging that imitates the appearance of fine glass surfaces. Until now, special additives and dyes had to be added to the plastic granulate before moulding in order to achieve coloured Transparency effects the use of a masterbatch from PolyOne is now sufficient. In addition, users also save on further coating and processing methods.
The practicality of the PolyOne solution was demonstrated by the German plastics packaging specialist Sauer Polymertechnik GmbH from Neustadt near Coburg in a development project for a renowned manufacturer of body care products proven. This also showed that procurement processes, warehouse management and production have been simplified.
UV-resistant packaging in yellow, orange and pink
The aim of the co-operation project was to develop a new series of slightly transparent plastic containers for the OEM manufacturer's personal care products. This was tailored to the SmartBatch Frost Collection of PolyOne and subsequently selected Sauer Polymertechnik as a partner for the realisation of the product idea. In the project, PolyOne took on the task of developing specific Food-safe formulations for masterbatches in the three colours yellow, orange and pink. PolyOne also integrated an additive that ensures the UV resistance of the plastics processed with it. This protects the ingredients from spoilage and colour changes.
The masterbatches developed by PolyOne were tested at Sauer with both new and recycled PET material. At the same time, Sauer worked with the end customer to develop the Packaging design. The designers placed particular emphasis on the matt effect, which was intended to give the packaging an elegant appearance and attract the customer's attention. Finally, Sauer integrated the innovative masterbatches into its production processes for plastic bottles. A product sample was created for the end customer, which was ultimately well received and went into series production.
Alexander Umlauf-Sauer, Sales Manager at Sauer Polymertechnik, is pleased that the integration of the masterbatches into Sauer's production processes went just as smoothly as PolyOne had announced. The new range has also been well received by customers. The stable order figures and the favourable reactions are proof of this.
Easy to process
Sauer Polymertechnik's experience is now shared by other PolyOne customers. As the US supplier reports, the SmartBatch Frost masterbatches simplify the production of plastic packaging with a Retro effect frosted, translucent glass. Among other things, cost-intensive secondary glazing is saved. Manufacturing processes such as coating, spraying or wrapping the bottles with sleeves.
„The SmartBatch Frost masterbatches are easy to process because we don't have to mix them with other colourants and additives. This has significantly reduced our warehousing costs.“
Alexander Umlauf-Sauer, Sales Manager at Sauer Polymertechnik
Designers also enjoy significantly more design freedom. For example, textured surfaces can be produced easily without having to change the mould. The masterbatches are suitable for the production of drinks and water bottles as well as packaging for hair, skin and body care products.
A masterbatch for recycled and new PET
The new masterbatches can be processed on the same machines as conventional masterbatches. PET materials can be processed. PolyOne supplies its products as granules or in liquid form, depending on customer requirements.
The sustainability of plastic packaging is becoming increasingly important for manufacturers, retailers and consumers. PolyOne has also made provisions for this. The SmartBatch Frost masterbatches can also be used with rPET, as well as with new plastic material. With recycled PET, toner may need to be added in order to optimise the Colour shades of the masterbatch and the recyclate. In addition, the use of PolyOne masterbatches does not affect the Recyclability and the original material properties of the products manufactured with it.
