HOW TO SUCCESSFULLY
INTEGRATE MORE
RECYCLED CONTENT
INTO YOUR PACKAGING
HOW TO SUCCEED WITH rPET
Market demand for more sustainable packaging is here to stay. A successful rPET solution needs to address all stages of production in order to
To remain competitive and deliver on this demand, you must adopt achieve the desired quality, consistency, part cost and system performance. Husky has
manufacturing processes that enable the integration of more rPET developed a unique, proven rPET strategy that focuses on all stages of production:
into your packaging. Consumer demand paired with upcoming
legislations requiring higher percentages of recycled content in Pre-melt
packaging already have industry-leading brands taking the lead.
How do you ensure you don’t get left behind? Here’s what you need
Melt delivery
to consider to successfully integrate more recycled content into
your packaging.
Preform production
Downstream processing
THE CHALLENGES OF rPET Holistic system monitoring
There are a few challenges to consider when using rPET material. These include:
• Variability - rPET collection and manufacturing technologies result in more
variable properties that can negatively influence material color, melt, and
dryingReduce energy use during startup
• Contaminants - melting recycled plastics can cause volatile organic compounds
to be released
• Dust creation - rPET processing can create increased dust that can build up in
mold cavities and affect mold performance and part quality
Despite these potential issues,
implementing recycled content
can be a smooth process
with the proper planning, right
technology and a partner with
rPET proven experience.
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PRE-MELT MELT DELIVERY PREFORM PRODUCTION DOWNSTREAM PROCESSING
The pre-melt stage sets the tone for the entire Use built-in technology in your hot runners to Implementing a proactive mold cleaning process Even with the processes listed throughout this guide,
molding process. Here are four tips for success in proactively reduce the accumulation of PET dust. will help you successfully run rPET during preform continuing to monitor for defects is important for
the pre-melt stage: Using high amounts of rPET content can increase production. Consider these factors surrounding the success when integrating rPET into your package
dust deposits in mold vents. While vacuum mold cleaning process: manufacturing. You can easily do this with integrated
• Use a fully-integrated dryer that can detect technology can be used to counter this issue, it downstream monitoring equipment. This will catch any
and automatically adjust to machine doesn’t reduce the amount that builds up in the • Schedule regular cleaning to ensure dust and part quality issues before they enter the supply chain by
changes or resin variability, which allows cold half. You should also consider the root cause residue are proactively removed from vents detecting and flagging potential issues. These include
you to dry rPET at a lower temperature for a of dust creation to eliminate the need for additional before it results in defective parts persisting solid contamination, black specs, bubbles,
longer period of time. Because rPET is more vacuums and ensure there is controlled and haziness, color variations, as well as injection defects
sensitive to thermal degradation, it needs to • An automated process simplifies cleaning,
consistent melt delivery to each cavity. as opposed to manual processes that result on the sealing surface and gate area.
be properly dried to avoid processing and
quality issues. in significant downtime and potential mold
damage if not done properly
• Ensure your hopper diameter is optimized
for internal air flow distribution to allow for • Be consistent with your cleaning to ensure SYSTEM MONITORING
longer drying times. the entire mold is clean and stays clean
Holistic monitoring of the entire production process is
• Install an oil condenser that is fully integrated • Automated cleaning, such as Husky’s the last vital step to achieving quality, consistency and
with dryer controls, which allows the system revolutionary Self-cleaning Mold Technology, system performance. Operating at optimal standards
to be selectively used when processing rPET. simplifies the mold cleaning process to the while managing sustainability requirements requires a
This effectively reduces energy consumption touch of a button deeper level of understanding not just of the complete
and costs. molding process, but of the unique considerations
of running rPET material. A real-time equipment
• For a consistent melt when using rPET, use a monitoring system will allow you to proactively
gravimetric blender in the main hopper with intervene to correct issues before you see degraded
integrated dryer controls and system HMI performance.
and choose the proper screws and extruder
sizes. Husky’s Advantage+Elite proactive, predictive,
transparent monitoring solution is able to detect
changes in part quality and cycle time by monitoring
leading system variables to identify the root cause
of issues. By optimizing the process to manage
conditions, producers can maintain world class OEE
standards while producing rPET preforms.
4 | Guide: How to successfully integrate more recycled content into your packaging Guide: How to successfully integrate more recycled content into your packaging | 5
HOW HUSKY ENABLES YOUR
SUCCESS WITH rPET Get started
If you are looking to integrate recycled content into your packaging,
A good partner is crucial when it comes to adding more recycled content into your
selecting an experienced partner who has rPET proven technology,
packaging. Your experienced partner should have:
expertise and services is vital to enabling your success while
• The expertise to deliver a complete holistic solution from concept to completion maximizing quality and minimizing risk.
• The experience and ability to configure the most appropriate system for your Would you like to add rPET to your molding operation?
application and rPET content requirements
Contact us to learn more about how Husky’s solutions can help
• Proven and reliable equipment to deliver high productivity, low part cost and a
you achieve your current and future rPET goals.
wide processing window
• Streamlined system operation with easy-to use, intuitive features
• Engaged service and support to help you avoid unplanned downtime, prevent Get in touch »
expensive repairs and keep your manufacturing operations on schedule
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6 | Guide: How to successfully integrate more recycled content into your packaging
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