Zero Waste Cup collaboration
An example of what MuCell and EcoCore can achieve for packaging

SEE how Trexel’s MuCell® process enables Bockatech EcoCore® packaging. Trexel will be producing a foamed EcoCore reusable cup with 70% density reduction and a cycle time of 7 secs (including IML) on an ALLROUNDER 520 A packaging machine from ARBURG.

The cup is the result of a collaboration between a group of leading manufacturing technology, material and label providers developed and owned by company Bockatech®.

The low-cost reusable and recyclable cup weighs less than many single-use paper alternatives and features strong skin-foam-skin walls moulded in seconds.

As polypropylene is used for both the cup and label the container is easy to recycle at the end of its life.
The cup is over five times stronger than a plastic cup of the same weight and offers twice the thermal insulation — keeping drinks hot and fingers cool. Insulation also helps reduce condensation and water dripping from the outside when the cup is used for ice-cold drinks.

Discover other areas where foaming makes the difference while discussing with the experts!

Partners

The innovative container uses optimised polypropylene (Borealis), in-mould labels (MCC Verstraete), injection moulding (Arburg), Robotics (Roboplas) and physical foaming (Trexel MuCell®) along with a new foam manufacturing technology (Bockatech EcoCore®).

Electric injection moulding machine (IMM)

ARBURG is one of the world’s leading machine manufacturers for plastics processing and is a pioneer in the fields of production efficiency, digitalisation and sustainability. The product portfolio includes ALLROUNDER injection molding machines, freeformers for industrial additive manufacturing, robotic systems and customer- and industry-specific turnkey solutions. The ALLROUNDERs in “Packaging” design and the CUBE series for molds are especially intended for the packaging industry. For service and sales, ARBURG has its own organizations in 25 countries at 34 locations and is represented in over 100 countries together with trade partners. Production takes place exclusively at the German headquarters in Lossburg.

www.arburg.com

EcoCore® foam manufacturing technology

Bockatech is a growth Greentech company that provides innovative EcoCore plastic foam manufacturing technology for injection moulding under licence to packaging manufacturers and brands. EcoCore is helping some of the world’s leading food-service and FMCG brands create more sustainable high performance yet low-cost thin-wall and reusable packaging. EcoCore creates more sustainable innovative packaging with a competitive edge for a wide range of sectors and applications, including retail food, caps / closures, food-service, paint / industrial pails and healthcare. 

www.bockatech.com

EcoCore® foam manufacturing technology

Bockatech is a growth Greentech company that provides innovative EcoCore plastic foam manufacturing technology for injection moulding under licence to packaging manufacturers and brands. EcoCore is helping some of the world’s leading food-service and FMCG brands create more sustainable high performance yet low-cost thin-wall and reusable packaging. EcoCore creates more sustainable innovative packaging with a competitive edge for a wide range of sectors and applications, including retail food, caps / closures, food-service, paint / industrial pails and healthcare. 

www.bockatech.com

Optimised polypropylene

Borealis is one of the world’s leading providers of advanced and circular polyolefin solutions and a European market leader in base chemicals, fertilizers and the mechanical recycling of plastics. We leverage our polymers expertise and decades of experience to offer value adding, innovative and circular material solutions for key industries. In re-inventing for more sustainable living, we build on our commitment to safety, our people and excellence as we accelerate the transformation to a circular economy and expand our geographical footprint.

www.borealisgroup.com

In-mould labels

MCC Verstraete is a global supplier of premium IML label solutions. They have over 30 years of experience in offset-printing labels for injection molding, blow molding and thermoforming. In-depth understanding of materials, innovation and sustainability has made MCC Verstraete a world leader, producing over 60 million in mold labels every single day for numerous segments within the packaging industry.

www.mcclabel.com

In-mould labels

MCC Verstraete is a global supplier of premium IML label solutions. They have over 30 years of experience in offset-printing labels for injection molding, blow molding and thermoforming. In-depth understanding of materials, innovation and sustainability has made MCC Verstraete a world leader, producing over 60 million in mold labels every single day for numerous segments within the packaging industry.

www.mcclabel.com

Robotic cup removal and label placement

ROBOPLAS has more than 15 year’s experience in innovative design and manufacture of high-speed robots and automation systems for rigid packaging. We develop highly flexible in-mould label (IML) Robots for the manufacture of various products. The ROBOPLAS IML System can be prepared and changed rapidly between various product sizes and different cavity numbers. The ROBOPLAS IML systems we deliver are successfully used by our customers all over the world. Currently companies in more than 35 countries use ROBOPLAS IML systems and automation.

www.roboplas.com

Trexel MuCell® physical foaming

Outstanding expertise to achieve the most green and economic plastic parts. Our physical and chemical foaming solutions enable lighter, more dimensionally stable products which can be produced faster on smaller, more energy efficient equipment. Trexel is much more than a technology and equipment supplier. We leverage our 20+ years of foaming expertise in providing a full range of services to support you from exploration to design through serial production to ensure your program’s success. Meet us at K show, Düsseldorf October 19th to 26th, Hall 13, B46.

www.trexel.com

Trexel MuCell® physical foaming

Outstanding expertise to achieve the most green and economic plastic parts. Our physical and chemical foaming solutions enable lighter, more dimensionally stable products which can be produced faster on smaller, more energy efficient equipment. Trexel is much more than a technology and equipment supplier. We leverage our 20+ years of foaming expertise in providing a full range of services to support you from exploration to design through serial production to ensure your program’s success. Meet us at K show, Düsseldorf October 19th to 26th, Hall 13, B46.

www.trexel.com

Visit our Partner Booths to see and discuss the following

Borealis

Hall 6 | Stand A43

We invite you to “Innovate Collaborate Accelerate” together by visiting Borealis and Borouge to see a new reusable and fully recyclable lightweight bottle (made with the MuCell® process) made from Bornewables portfolio of polyolefins using renewable feedstock derived from waste and residue streams.

SUMITOMO Demag

Hall 16 | Stand CE13

Marking another advance in sustainable packaging, Sumitomo (SHI) Demag also features prominently at the VDMA Circular Economy Forum. Located in the outdoor pavilion area, visitors will get to see an IntElect S 180 featuring an advanced IML process combined with Trexel’s MuCell® technology producing hinged flip top lids for baby milk powder containers. The 3D visual effect as well as the weight reduction of round about 10% are enabled by the integrated MuCell foaming technology

SUMITOMO Demag

Hall 16 | Stand CE13

Marking another advance in sustainable packaging, Sumitomo (SHI) Demag also features prominently at the VDMA Circular Economy Forum. Located in the outdoor pavilion area, visitors will get to see an IntElect S 180 featuring an advanced IML process combined with Trexel’s MuCell® technology producing hinged flip top lids for baby milk powder containers. The 3D visual effect as well as the weight reduction of round about 10% are enabled by the integrated MuCell foaming technology

ENGEL

Hall 15 | B42, C58

Engel will be presenting the results of its collaboration with Faurecia, a FORVIA Group company to produce lightweighted automotive parts with Class A surfaces. A long awaited breakthrough in the history of foaming. See the highly integrated Engel Foaming optimized injection molding system, powered by Trexel at the Engel booth. A highly reduced footprint due to less material consumption, smaller machine tonnage and much lower energy consumption needed is only one of the major outstanding results.

FCS ( Fu Chun Shin )

Hall 12 | B80

Learn about FCS’s Gentrex shoe mid-sole automated production solution (foaming with the MuCell® process) with various samples on display to densities as low as 0.2 g/cc.

FCS ( Fu Chun Shin )

Hall 12 | B80

Learn about FCS’s Gentrex shoe mid-sole automated production solution (foaming with the MuCell® process) with various samples on display to densities as low as 0.2 g/cc.