In recent years we have found an increasing number of our customers are asking us to manufacture thermoformed products for them ahead of the time they are needed. We are required to store finished goods, on their behalf, so that they can be ‘called off’ as a just in time service. As a result we have had to utilize more and more factory space for the storage of finished goods.

At times during 2011 we were getting quite close to capacity for the amount of goods we could hold on to, such is the demand for this service. As a consequence we took the decision at the end of last year to acquire an additional unit adjacent to our premises. This has now been completely refurbished and fitted with racking capable of storing 500 pallets. A high speed pallet wrapper was also installed and access from the main factory has been opened up to provide a streamlined process from the end of line direct to the storage facility.

This new 10,000 sq ft dedicated unit is temperature controlled for optimum storage conditions and takes our storage capability up to a 1000 pallets of finished goods at any one time. Give us a call to discuss your requirements for finished goods storage on 0161 442 1642. This service can be a real boon for customers with limited storage capability and for those times when high volumes of product are required in a hurry.

Tricel blister packs are a variation on the Clamshell blister pack format. Tricel is a Macpac registered trademark and is the name given to a versatile blister packaging format that can either free stand or be hung from a Euroslot.

Tricel blister packs are ideally suited to heavier products and the format gives depth and definition to products making them look more attractive at the point of display. High levels of security can be incorporated using Macpac’s stud fix closure mechanism that is simple in its design but difficult to compromise. HF or ultrasonic welding can afford even higher levels of security. Graphic insert cards can be designed to enhance the presentation and they are simply removed post purchase for perfect waste segregation and recycling without any contamination of paper/board with plastic.

Macpac Tricel clamshell blister pack

The ability of Tricel blister packs to free stand means that they can be used as counter displays and can be positioned in eye catching ways in retail environments. They can also be used in a variety of creative ways for product launches and promotions.

Sometimes known as clam packs or clam cell blisters; Clamshell blister packs are high visibility thermoformings ideally suited to top quality point of sale display packaging. Here at Macpac we refer to most of our clamshell blisters as Eurocels. Eurocel is a registered trademark of Macpac. The clamshell blister pack affords much greater versatility than the simpler heat sealed blister pack. Clamshell blisters are thermoformed from a single sheet of film, typically APET or RPET and incorporate a hinge that enables the forming to be folded back onto itself to fit snugly around the product. A closure mechanism can be designed into the forming as an integral part of the pack as either a clip fix or stud fix system for added security. The edges of the pack can also be HF welded or ultrasonically welded to give an even greater level of security against pilferage, which is especially important for products of higher value.

Clamshell blisters are well suited to larger heavier products that would be difficult to pack in heat sealed blisters or other thermoformed packaging. They offer a lot more scope for high quality point of sale presentation especially when incorporating really good design. Clamshell blisters can have more of a 3 dimensional aspect and the front and back of awkward product shapes is easily accommodated to give a snug fit for a really professional appearance. A euroslot can be incorporated into the design so that packs are easy to hang at the point of display.

Graphic insert cards can be designed around the product to complement and add to the display for maximum effect. Clamshell blisters are very easy to recycle because the graphic inserts are easily segregated from the film with no contamination. By incorporating the use of recycling symbols into the design of the clamshell the product’s brand owner demonstrates a recycling philosophy that is likely to be in keeping with the corporate image they wish to portray as well as being attractive to their customers.

A variation on the clamshell blister pack is the Tricel pack. This is a clamshell that can be made to free stand or hang, but more about these really nifty packs in our next post.

The heat sealed blister is by far the most common type of blister pack in use globally and as a consequence could almost be considered to be the generic form of the blister pack. Sometimes known as the carded blister it provides a simple and versatile solution to presenting a vast array of products at the point of sale giving good product exposure and a reasonable level of protection. In its simplest form the product sits on a pre-printed backing card and a preformed plastic (typically APET) shape (blister) is positioned over the product and sealed to the backing card using heat.

The use of good design on the backing card enables a product to stand out on the shelf or in display and is an integral part of a products marketing. The card can incorporate a Euroslot to facilitate shelf hanging which is one of the most efficient methods for retailers to store stock and present products at the point of sale. Macpac will design and produce backing cards as well as designing and manufacturing the entire pack if required.

The thermoformed plastic shape can be made to fit practically any product to give a secure tight fit when sealed to give product protection. Macpac produce all tooling for these shapes in-house thereby keeping costs down whilst speeding up time to market. In addition to bespoke pack design Macpac also supply a range of standard stock sizes for ease and simplicity. The plastic used for most of Macpac’s output is either APET or RPET. Both materials offer high clarity and can be supplied with a slight blue tint that accentuates the appearance of many products making them even more appealing on display.

Heat sealed blister packs can be recycled easily after use by separating the backing card from the thermoformed shape. One slight downside to the recycling process is that of minor board contamination of the plastic edge where the seal is made to the board. For a completely recyclable option to heat sealed blisters the clamshell pack presents an excellent alternative.

Macpac has its fair share of keen cyclists. Some prefer the road and some prefer the relative safety (from other road users) of off road cycling. Both disciplines are encouraged on the grounds of healthy minds and bodies make for a healthy team of thermoformed packaging specialists.

During the current spell of Indian summer weather we’re taking every spare time opportunity to ride the Cheshire lanes not far from our newly refurbished factory. As a result we’ve noticed an increase in abnormal sized traffic. Huge tractors with harvesting equipment akin to medieval torture treatments are rattling around the lanes gathering in the harvest. Because of this we thought it was worth a timely reminder to be extra careful if you ride in rural areas. Some of you might have only recently discovered the joys of cycling and may not be aware of the dangers of tortuous country lanes and huge mechanical behemoths dragging along tons of crops whilst taking up most of the road. For those that are please remember to be extra careful and always wear a helmet.

Earlier this year Macpac company secretary Sarah Kershaw got the cycling bug from husband and Macpac M.D. Graham Kershaw. Graham is an off road specialist and has covered most of the toughest mountain trails the UK has to offer. He can often be spotted hurtling through the Macclesfield Forest in the dead of night with his Hope Technology lights to guide him. Sarah on the other hand has become a devotee of road cycling. After just a few months in the saddle she successfully met the challenge of the Manchester 100 on a pleasant Sunday morning in September. This annual event supports the Christie cancer charity and offers riders the choice of 100 mile and 100 kilometre routes through the Cheshire countryside. Sarah opted for the shorter route this year but has vowed to attempt the 100 miles next year and raise money for the cause.

Sarah successfully completes 100km

The first weekend of October presented Sarah with her second official cycle challenge as she entered the Northern Cycletta women specific event. The Cycletta starts and finishes in the historic Tatton Park and aims to increase cycling participation by the fairer sex. Over a thousand riders including Olympic gold medallist Victoria Pendleton supported the 40 km event. The organisers hope to run along closed roads next year.

Welcome to the third and final part in this series of how to choose a thermoforming supplier.

Responsibly sourced materials:

The quality of raw materials varies from supplier to supplier. As there is a much higher quantity of recycled material in the system than ever before, a fact that should be applauded, it is especially important to be sure that your new supplier sources material not just on the basis of cost but on quality also. Ask them about the materials they buy. If they respond strongly stating ‘they buy on price to keep cost down for their customer’ it might sound good but it’s only part of the message you should be getting. A more compelling answer would be that ‘there are only a few suppliers of recycled material such as RPET trusted to supply the quality our customers expect. There is plenty of substandard material out there but it compromises quality and should be viewed as false economy.’ Once you’re working with a supplier that doesn’t compromise quality for price you’re more likely to be working with a supplier you can trust to satisfy your needs.

Recycling credentials:

This might not be high on your list of priorities when identifying a new supplier but for some companies they will only work with suppliers that demonstrate ethical operating policies including their approach to recycling. If you’re one of these then we’re preaching to the converted but if you hadn’t really given it much thought perhaps now’s the time to do so. Companies with ethical operating procedures tend to make for better quality suppliers as a result of the high standards they set and strive to meet and maybe also partly because they care that little bit more. Ask your new supplier how much recycled material they use and if they still use materials such as PVC and even what their thoughts are about this material. APET and RPET, the recycled form of APET has largely taken over from PVC in thermoforming as it is seen as a more environmentally friendly alternative. Ask them also what they do with their scrap. If they segregate waste ready for chipping on site, it suggests more concern about recycling. Ask them also about using the recycling logos on packs and if they encourage their use in customer designs. The better companies will have stock graphics with these logos already produced. They will also appreciate the value a recycling symbol can bestow to your product and reinforce the recycling message.

Operating Standards:

Manufacturing businesses need standards to maintain quality but it’s surprising to see how many companies don’t work to any formal standards. The benchmarks for standards relating to quality management are the ISO 9000 standards and are designed to meet the needs of customers’ quality demands. The ISO standards have been around for over 20 years and have been refined and updated throughout this period. Ask your potential new supplier how long they have been ISO recognised and what they think about it as a standard. They should really be displaying a certificate of their accreditation within their premises as you might expect of any proud supplier. Another important accreditation for a supplier to have is the BRC/IOP accreditation. If your products are at all food related then your new supplier should really have this accreditation but it’s surprising just how many don’t have it. Beware those that don’t as their operating procedures are likely to be lax and their materials may be sub standard and not even food grade.

Going the extra mile:

Companies that can go that extra mile to guarantee quality of service generally stand out as the successful companies. Typically they provide services over and above the norm such as contract packing and printing services. Some even offer to help with product assembly as part of the packing and fulfilment exercise. Will your new supplier manufacture your goods and hold them for call off if necessary? and do they have the necessary storage space to offer this service? What are their delivery terms like and can they turn a job round quickly if required. Could they supply you with welding jigs shuttles and add-on tools? Can they HF weld packs and do they have a facility to weld packs using ultrasonic techniques? These are all factors to consider before choosing you new thermoforming supplier.

Welcome to part 2 in this 3 part series about how to choose a new supplier

Design Capability:

If you’re looking for bespoke thermoformed packaging the design element is an essential part of the process. Good design makes for great looking functional packaging with integrated cost effective manufacture. A company that can offer creativity and experience as well as a cost conscious approach is likely to satisfy your requirements time and again. Ask a potential new supplier if they use Solidworks software for the design process and whether they can produce virtual 3D presentations. The ability to do this indicates a company that keeps pace with technology and will present concepts to you that make final decisions so much easier and quicker. Ask them as well if they could incorporate your product into the pack design to see how it would look as a finished pack at the point of sale. Another point to factor in is whether they have the capability to design and produce all the printed inserts and other printed matter. It’s a really important to ensure that the pack design is complemented by the print.If they can do this they should more than satisfy all your needs.

Tooling Capability:

Good quality tooling reflects on the quality of final products. There are lots of tooling companies throughout the UK but very few thermoforming companies that have a truly comprehensive tooling facility in-house. The in-house operations have more control over the tooling production aspect of any given project. This helps to move jobs through the production process far quicker than outsourced tooling jobs as well as ensuring high standards of quality control. Not all tooling facilities are well equipped and many of them don’t utilise the latest CNC milling techniques so it’s really important to ask a new supplier how they make their tools. Many of them will be using outdated casting technology that produces low quality tools that might look attractive from a cost perspective but the reality is that you will pay further down the line with sub-standard quality and poor finished packaging – just not desirable or acceptable in today’s marketplace. Ask a new supplier for a trip round the toolroom if they have one and make sure they run automated milling operations.

Manufacturing Capability:

OK so you’ve got a really good design and the tools laid down are of the right quality at a sensible price. The next stage is to ensure that the machines and their operatives are up to the task of converting the design into quality finished products quickly and cost effectively. Old vacuum forming machinery is generally less energy efficient and slower in operation. It’s unlikely to produce the detail in engravings of text and logos that newer machinery can easily handle. Its important to make sure that your new supplier operates good quality machines. Ask them how old their machines are. Anything over 6 or 7 years is getting a bit long in the tooth. What you’re really looking for is modern pressure forming machines rather than vacuum formers. Pressure formers are able to provide fine detail and can produce sharp angles and undercuts. If you find a company with these types of machines not more than 4 years old then you should be assured of quality if everything else is in place. If you see Illig machines you’ll know you’re on the right track as these German manufactured machines are considered amongst the best in the thermoforming industry.

In part 3 we will look at some of the more ethical aspects of how companies operate and the standards they work to in order to ensure high quality for their customers.

Choosing any new supplier can be a daunting process, especially if you’ve had a bad experience in the past. It’s important to do your homework on any potential new company before engaging their services particularly if they could affect your ability to deliver a high quality service to your own customers. Packaging is an important factor in presenting your products to a high standard at the point of sale or protecting them in transit. You’ll want to ensure that quality and timely delivery at the right price become a given from your new supplier and they will be if you choose wisely.

We thought it would be helpful to draw up a list of 9 factors to consider in choosing a new thermoforming supplier. The first 3 are appropriate for any new supplier selection whilst in parts 2 and 3 we list considerations that are thermoforming specific.

1. Financial Stability: There’s little point in choosing a supplier if they are likely to be here today gone tomorrow. Building a new supplier relationship should be the start of a long term partnership. If the company you choose has money problems it’s likely to affect their ability to buy raw materials to fulfil your contract causing delays. It’s also likely to affect their ability to negotiate good prices so you may end up paying over the odds. A visit to their premises is often a useful indicator but far from foolproof. You will though get a ‘feel’ for the way a company operates and whether or not they seem to be running a shoestring operation. To get a really good financial picture you need to do a little digging. The good news is that with the internet it isn’t so difficult or costly. There are scores of credit rating companies that will provide information. Your bank is always a good place to start, as they should have a vested interest in your financial security. For a small fee you can get a comprehensive credit check for peace of mind. You probably wouldn’t give a new customer extended lines of credit so why would you trust supplier’s finances.
2. The 2 R’s – Reputation and Reliability: A good reputation is founded on reliability. The old saying ‘you’re only as good as your last job’ is a constant reminder to maintain reliable high standards and a good reputation. Successful companies develop good reputations through consistency over a long time but how do you assess a company for suitability as a reliable new supplier? Well for a start the company website can be quite revealing. Have a read of the ‘About Us’ page if they have one. Look out for testimonials from satisfied customers or case studies that give more detail about the supplier’s competence. Try contacting one or two of these companies and speak to someone about their experience with the supplier. You could also try speaking to the editors of trade magazines for the relevant industry. The Packaging industry has 2 main magazines serving it – Packaging News and Packaging Today. There are a number of other magazines that are more dedicated to certain sectors of the industry such as Retail Packaging, the editors of which are well worth talking to.
3. First Impressions: Yet another old saying ‘You only get one chance to make a first impression’ comes to mind. When you phone a company for the first time do they answer promptly? Are they courteous, clear and polite and most important of all are they able to deal with your enquiry or put you in touch with the appropriate person straight away? All sounds pretty simple doesn’t it but all too often companies fail at the first hurdle to impress a potential new customer. A slick operation from the reception onwards suggests you’re dealing with a company that sets high standards, is keen to maintain them (back to reputation again!) and eager to please – makes for a good start in any new relationship.

Part 2 of this article majors on design and manufacture of thermoformed packaging and trays and will be posted in the next day or so.

Here at  Macpac we are delighted to announce the acquisition of the Northampton based business of Hamilton Plastic Packaging.

A seamless transfer of all production from Northampton to Macpac’s newly refurbished manufacturing facility at Stockport has been scheduled for completion by the end of August 2011. The Hamilton sales team have been retained and will continue to operate as previously for the benefit of all customers.

Both companies operate Illig thermoforming machinery so all tooling owned by Hamilton customers will be completely compatible with Macpac’s machines. This was a major factor for consideration in the purchase and part of a package of measures to ensure that Hamilton customers continue to receive an uninterrupted and expected high level of service without any additional cost.

The added bonus for Hamilton customers is that Macpac’s machines are newer and feature pressure forming for improved quality and lead times. They have just taken delivery of a new RV74c pressure former making it the fourth new machine to be brought into service in the past 2 years. Macpac’s in-house design and tooling division will also be a major asset for Hamilton customers with new projects to consider. The toolrooms are equipped with 24 station CNC machinery for the fast production of precision tooling. Macpac can also offer substantial warehousing space for storing high levels of finished goods as well as a contract packing service, a facility previously not available in-house from Hamilton.

Hamilton managing director Andrew Sidders (pictured left below) emphasised the importance of finding the right company to ensure his customers receive continuity of service and access to advanced facilities. He also expressed his thanks to all customers for their support over the years.

Macpac managing director Graham Kershaw (pictured right above) stated his delight at the purchase and that the Hamilton customer base was a perfect fit with that of Macpac’s. He went on to say that ‘over the coming weeks we will demonstrate our capability to all Hamilton customers putting new and improved services at their disposal. The fact that we are BRC/IOP accredited should immediately reassure any food industry customers of our credentials. We’re really looking forward to working with our new customers and helping to improve their businesses’.

We’re often asked this so we thought we’d provide a simple explanation. Thermoforming is the shaping of plastic sheet material using sufficient heat to make the plastic pliable enough to stretch it onto or into a moulded profile. Once the shape is formed and allowed to cool it can then be trimmed into a useable product – typically blister packaging, clampack or clamshell packaging or display/transit trays. Thermoforming then, could be considered the generic term for converting plastic sheet into products using heat. Vacuum forming is a further stage in the process such that when the heated sheet is positioned over the mould a vacuum is introduced to remove any trapped air as the film is drawn to the mould. This enables the shape of the mould to be more accurately replicated thereby improving quality. Pressure forming takes this process a stage further by introducing compressed air to the topside of the sheet to help force the sheet into the mould. The additional pressure allows thicker gauge material to be formed with more intricate detail and sharper corners. It will give really good definition on engravings and raised areas such as text and logos and will even allow undercuts and negative angles to be formed. Modern thermoforming machinery is highly engineered and generally incorporates vacuum technology as standard. Pressure formers tend to be larger and more sophisticated machines and consequently are more expensive so not all thermoforming companies will have them at their disposal. Here at Macpac all our machines are supplied by German manufacturer Illig, widely acknowledged as a leader in the thermoforming sector. We are constantly investing in new machines to ensure that we have the most advanced and energy efficient machines available. During 2010 we undertook a £0.75m factory refurbishment and installed 2 new pressure forming machines, the RD53c, the first of its kind in the UK and an RV74c.

These machines are at the forefront of thermoforming technology and enable us to provide very high quality thermoformings at competitive prices with the added flexibility of being cost effective for short batch runs as well as production volumes into the millions