Ararat Vacuum Forming Packaging Industries
- Vacuum forming packaging services(card, press, clamshell, stand and skin)
- Production of Vacuum Forming Parts in ABS, HP, PET, PVC.
- Manufacturing of Die-Cut Boxes with Printing.
- Design and manufacture of CNC vacuum forming molds
Ararat is chosen by the best
Ararat Vacuum Forming
Ararat Vacuum Forming and Packaging Industries, under the management of engineer Levik Shirvanian, thanks to God, has a successful history and experience in providing vacuum forming packaging services for more than 22 years. With technical knowledge and experience, it is one of the leading companies in this field and has the honor of cooperating with prominent brands such as Daily Dairy, Bell Dairy, Bloor Kaveh and My cosmetic products.
Ararat with 22 years of experience. In the field of vacuum forming packaging, it is known as one of the top companies in this industry. This company provides high-quality packaging services to its customers with the efforts of expert personnel and using advanced equipment.
Using new technologies, we guarantee the quality of our products and services. We offer to customers. Also, by using advanced equipment, in a professional manner and with high precision, we pack and present the products desired by the customer.
Ararat Vacuum Forming, based on ethical and professional principles, works with our customers to meet their needs. Cooperates in all stages of work. By providing quality services with accurate delivery schedule, this company has been able to gain a superior position in the vacuum forming packaging industry.
During the past victorious years until today, Ararat, with its history and experience in this field, has always It is trying to gain the trust and satisfaction of its customers by providing high quality services at reasonable prices and make the dream of reaching the top rank in the packaging industry a reality.
We are on this path. We will remain steadfast.
Why Ararat?
More than two decades of scientific and technical experience
We have more than 22 years of experience in the vacuum forming packaging industry and are one of the top companies in this field.
Quality Guarantee
Using new technologies and skilled professionals, we guarantee the quality of our products and services.
Advanced and Accurate Production Line
The devices and machines of our production line follow the latest technology in the world.
Unique Consultation, Design, and Implementation
Ararat works by your side from 0 to 100 to achieve the best result and final product.
Use of high-quality raw materials
We use quality raw materials in our production so that the quality of the final product is optimal.
High production capacity
Our production line has a high capacity and has the ability to respond to large customers.
Customer satisfaction efforts
We are always trying to gain the trust and satisfaction of our customers by providing quality services at reasonable prices.
Precise scheduling
By providing services with accurate delivery schedule, we meet the needs of customers in all stages of work.
Utilizing state-of-the-art technology
We have always tried to keep our awareness and knowledge up to date by researching our work.
Our services include
Our Portfolios
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Vacuum Forming
Vacuum Forming In a simple definition, it is a simple method for shaping thermoplastics and thermoplastics, which we use to produce shaped parts for packaging goods and various products.
This method is one of the best and most cost-effective methods for producing transparent, resistant, flexible, precise, engineered, beautiful and low-cost plastic packaging.
Vacuum packaging Forming with a variety of CNC mold designs and the use of thermoplastic PET, ABS, PVC raw materials and HP polystyrene for packing all kinds of fruits, nuts, Packaging of chocolates and sweets, eggs, other food, accessories Cosmetics, tools, electronic and automotive products, all kinds of toys and the production of all kinds of plastic parts and disposable containers are used.
Greetings, welcome to Ararat Packaging Industries website. In the following, we intend to provide information about the subject of “Vacuum Forming” and “Vacuum Forming Packaging“.
It is hoped that this content will be useful for you dear ones and will be a good advice for your product packaging. Stay with us…
Table of Contents
What is vacuum forming?
Vacuum forming is a process in which a thermoplastic or thermoplastic sheet becomes malleable and flexible with a certain temperature, then the thermoplastic is molded into a mold by an aluminum mold and negative air suction.
In the vacuum forming process, an aluminum or (wooden) mold is first designed for the desired part or product, then this mold is connected to the vacuum forming machine.
Depending on the customer’s needs, a roll of plastic sheet with a certain diameter made of PET, PVC, HP, ABS or other thermoplastics is connected to the sheeting part of the machine.
The vacuum forming machine opens the thermoplastic sheet roll and heats it in a chamber so that the sheet is heated and softened. Then, by moving the mold towards the softened sheet, the sheet takes the shape of the mold and is quickly emptied by a vacuum valve between the mold and the sheet. In order to maintain this condition, the plastic sheet is quickly cooled and separated from the mold, and then it is directed to the cutting part.
Types of vacuum forming
Vacuum forming packaging process
Vacuum forming packaging has different stages that we have divided these stages into three parts. Stay with us to review these sections and steps.
The first part (initial steps):
Product review
First, the product for which we want to prepare the packaging must be completely examined in terms of size, weight and volume in order to obtain the information needed to choose the type of plastic sheet and make the mold.
Determine the type of plastic sheet
The plastic sheet for packaging should be selected according to the type of product, for example, sanitary sheets should be used for food products, and thick sheets should be used for products that are relatively heavy. Plastic sheets include: ABS, HIPS, PVC, PET, each of which has its own characteristics, which we will discuss further.
mold manufacturing
The mold is the most important part of vacuum forming, which must be done very carefully, because the product packaging is formed with it. The mold is made according to the product and the customer's needs. Aluminum and wood can be used to make molds, wooden molds are used for prototyping and aluminum molds are used for large and high production.
The second part (main steps):
This section includes the main steps of plastic sheet forming, which is done by the operator and the vacuum forming machine.
Fixing the mold on the vacuum machine
The mold must be firmly and stably fixed on the mold of the device so that the forming process can be done correctly.
Placing the roll of plastic sheet in the feeding part of the machine
The desired plastic sheet is placed as a roll or sheet in the machine's sheet picker.
Heating the sheet
So, performing the initial steps, the main steps of forming the sheet begin with heating the plastic sheet, which is done with the device's heater.
The rise of the mold
After heating the sheet, the device raises the mold and sticks it to the heated sheet.
Vacuum forming and shaping
After the mold is attached to the sheet, the air between the mold and the sheet is drawn and discharged by the vacuum pump of the device. With this process, the hot sheet sits on the cold mold and takes the shape of the mold.
Cooling and releasing the formed part
After forming the sheet, the machine cools the formed part with water and air pistols, and then the part is released from the mold or so-called blow.
Cut the shaped piece
At the end, the shaped piece is cut by a cutter to separate it from the machine and the roll.
The third part (final stages):
This section includes the main steps of plastic sheet forming, which is done by the operator and the vacuum forming machine.
Cut additions
Here, the additions of the shaped part are done by special tools and devices, and if drilling is needed, it is also done at this stage.
Packaging and assembly
In the final stage, if there is a need to assemble parts or printed cards, it is done along with the final packaging of the product and the work is finished.
Advantages of vacuum forming packaging
Vacuum forming packaging with speed, efficiency, versatility and low cost is one of the best options for producing packaging parts. In this process, advanced technology is used, which is very suitable for the production of precise and high-quality parts. One of the advantages of this method is high speed and lower cost than plastic injection. For this reason, this method is considered one of the best and most effective methods for packing parts.
Save money
Vacuum forming packaging is a cost-effective way to display and sell your product. This type of packaging is more affordable than other packaging in the market due to the nature of the materials, design and production process. Because the production process and tools of this packaging are not particularly complicated and are relatively cheap.
Great advertising space
There is a suitable range of vacuum forming packaging methods that can be used in many designs and colors for product packaging.
For example, combined packaging with cardboard has a very suitable advertising space and this advantage can be used for brand insertion, advertising and marketing.
Manufacturers can use this method to display their products on the store shelves and even create a brand to increase the loyalty of their customers.
Transparent packaging
Vacuum forming packaging is transparent and allows customers to see the product and check its quality.
According to the research conducted, more than half of the buyers prefer to see the product before purchasing.
Therefore, this advantage encourages customers to buy and helps them a lot in making a purchase decision.
In a way, it can be said: this type of packaging is honest and does not lie!
Prevent theft
In retail stores, small and tiny products may be easily stolen.
For such products, special and appropriate size packages are designed so that the customer can only see the product and not be able to touch and feel it.
Therefore, this type of packaging, while being transparent, visible and resistant, can also maintain product security.
Prevent product tampering
For some products such as food or other products that can be copied or counterfeited, manufacturers can use vacuum forming packaging along with thermal stitching so that their products reach the customer intact and without tampering.
And to ensure that the product reaches the customer without tampering, defects, or counterfeiting, they can use a label titled "If the package is open or cut, stop buying it."
Product protection
Vacuum forming packaging is a very good protection for the product, which, while displaying, also preserves the durability and quality of the product well. This type of packaging is a cost-effective way to professionally market your product at a low cost.
High accuracy and speed
Parts and packages produced by vacuum forming process are much more precise and beautiful compared to the combination of multiple parts and products that are made by injection or molding.
Because they are made in one piece.
Vacuum forming reduces errors in the production process and there is no gap between the initial design and the final product.
Therefore, error reduction increases accuracy and speed and in some cases minimizes related costs.
Flexible design
In this process, due to the use of design and mold making and production of the initial product, the defects can be removed and finally the desired and suitable design is reached and after these steps the production can be started.
For this reason, this type of packaging has high flexibility in design and implementation.
Saving time
Because time is gold and it is somehow a cost! Vacuum forming is the most economical and fastest way to produce plastic parts and packaging.
This process is very simple and takes little time between the design and the final product.
This advantage allows you to package and present your product to the market in the shortest possible time.
Reduction of volume and transportation
Due to the small volume, vacuum forming packaging allows for the transportation of more products in one environment, which reduces the cost of transportation.
Extending the useful life of the product
By maintaining the freshness and quality of the product and preventing oxidation and decay, the useful life of the product can be increased.
Stylish and beautiful design
With precise and flexible design and shaping, this packaging can provide stylish and attractive packaging that helps display the product and can help attract new customers and retain existing customers.
Applications and uses
Product packaging and display
Nowadays, most of the products that we are in contact with and that play a role in our daily life are packed by vacuum forming method.
Products such as cosmetics, razors, toothbrushes and other consumables are often packaged and supplied by vacuum forming.
Sealing methods in vacuum forming packaging
As we said, there are different types of vacuum forming, each of which is sealed and assembled in different ways. Here we briefly discuss these methods, for more information, refer to the article on types of seals in vacuum forming.
1. High frequency welding
In this method, the product and a printed cardboard card are placed between two vacuum pieces, and then the two vacuum pieces are sewn together with a high-frequency welding machine to complete the packaging.
2. Heat press
In this method, the product is placed between a vacuum shaped piece and a printed cardboard card, and then the vacuum piece and the cardboard card that has blister glue are pressed together by a heat press machine.
3. Seal between cards
In this method, the product and the vacuum part are placed between a special printed card, and they are glued together with a special glue, you may have seen this method in the packaging of flash memories.
4. Sliding seal
In the sliding seal, as the name suggests, a printed cardboard is placed slidingly inside a vacuum piece that is bent on three sides. The product is placed inside the vacuum part, and then the cardboard is slid into the vacuum part.
5. Locking seal
The latch seal is used in hinged or clamshell vacuum forming packaging.
This packaging has a vacuum piece that is designed as a shell, and one side is the compartment and the other side is the lid. There is a protrusion on the sides of the door and a recess on the sides of the compartment, which makes the lid and the compartment lock together when closed.
6. food seal
Seals are used in food packaging. In this seal, a plastic sheet that is generally printed is sealed on a vacuum container with a special device.
Raw materials and vacuum forming materials
Thermoplastic, or thermoplastic, is a plastic polymer material that becomes malleable and soft by applying heat and hardens again after cooling.
In packaging industries and vacuum forming services, PET, PVC, HP and ABS thermoplastics are the most used.
In the following, we will examine these types of thermoplastics.
PET (Polyethylene terephthalate)
PET or polyethylene terephthalate is the most common thermoplastic of the polyester family and has a sanitary grade and can be used for food and medical packaging.
PET is a combination of excellent mechanical, electrical and thermal properties, along with very good chemical resistance and dimensional stability. It also has low moisture absorption and good flow properties.
PET thermoplastic has high resistance and strength and the possibility of very good processing and shaping, and it has features that distinguish it from other thermoplastics.
Application in packaging
Egg vacuum packaging, candy and chocolate stand vacuum packaging, health products and cosmetics, medical products, etc.
Attributes
- Very low moisture absorption
- With sanitary grade
- Exceptional dimensional stability
- Excellent electrical properties
- High resistance to chemicals and
- environmental pressure and cracking
- Heat resistance and temperature rise
- Very low creep and deformation, even at high temperatures
- Very good color fastness
- abrasion resistance
Physical characteristics
- Tensile strength: 2.5 N/mm2
- Impact resistance: 1.5 to 3.5 kJ/m2
- Molding temperature: 120 to 160 degrees Celsius
- Maximum heat stability: 70 degrees Celsius
- Density: 1.37 grams per cubic centimeter
- Thickness: 200 to 1000 microns
- Colors: transparent, white, black and other colors
Chemical resistance
- Dilute acid: Very good
- Dilute alkalis: moderate
- Oil and grease: Very good
- Fatty hydrocarbons: Very good
- Aromatic hydrocarbons: moderate
- Halogenated hydrocarbons: moderate
- Alcohols: Very good
PVC (Polyvinyl chloride)
PVC or polyvinyl chloride is one of the most widely used polymers in the world.
Due to its multi-purpose capabilities, PVC has many uses in various industries, including packaging.
This polymer is a very durable material and has a long shelf life, which is available in different thicknesses and colors.
Application in packaging
PVC is mostly used for packaging products such as electronic devices, tools and toys.
Attributes
- Good impact resistance
- Does not absorb moisture and water
- Easy processing and shaping
- It is hard and light
- It has a long shelf life
- Suitable for food packaging
- It is completely recyclable
Physical characteristics
- Tensile strength: 2.60 newtons per square mm
- Impact resistance: 2.0 to 45 kJ/m2
- Molding temperature: 140 to 190 degrees Celsius
- Maximum stability against heat: 60 degrees Celsius
- Density: 1.38 grams per cubic centimeter
- Thickness: 200 to 1000 microns
- Colors: transparent, white, black and other colors
Chemical resistance
- Dilute acid: Very good
- Dilute alkalis: Very good
- Oil and grease: Good
- Fatty hydrocarbons: Very good
- Aromatic hydrocarbons: Weak
- Halogenated hydrocarbons: moderate
- Alcohols: Good
HIPS (High impact polystyrene)
HIPS is one of the most widely used and popular plastics, which has a sanitary grade and has good resistance.
This thermoplastic is available in various colors and thicknesses from 200 to 1000 microns.
HP is easily malleable and has good flow and antistatic properties.
Application in packaging
Because this thermoplastic is hygienic like PET, it can be used to produce food containers and food packaging, medical devices, cosmetics and other products.
Attributes
- With sanitary grade
- Easy malleability
- Transparent and semi-transparent
Physical characteristics
- Tensile strength: 2.20 to 2.70 N/mm2
- Impact resistance: 10.0 to 20.0 kJ/m2
- Molding temperature: 159 to 170 degrees Celsius
- Maximum stability against heat: 60 to 80 degrees Celsius
- Density: 1.6 to 1.38 grams per cubic centimeter
- Thickness: 200 to 1000 microns
- Colors: transparent, white, black and other colors
Chemical resistance
- Dilute acid: moderate
- Dilute alkalis: Very good
- Oil and grease: medium
- Fatty hydrocarbons: Very good
- Aromatic hydrocarbons: Weak
- Halogenated hydrocarbons: Weak
- Alcohols: Weak
ABS (Acrylonitrile butadiene styrene)
ABS has very high impact resistance and has excellent surface quality, color stability and ideal gloss.
ABS is produced in 1 to 6 mil thickness and in white, black and gray colors.
This thermoplastic is easy to mold, absorbs moisture and is more expensive than other materials.
Application in packaging
Because of its high resistance, ABS is used to make household appliances, helmets, walls of electronic devices, internal parts of refrigerators, bathtubs, etc.
Attributes
- Very high resistance
- Color stability
- Quality and shiny surface
- Easy malleability
Physical characteristics
- Tensile strength: 40 to 50 Mpa
- Impact resistance: 10 to 20 kJ/m2
- Molding temperature: 150 to 180 degrees Celsius
- Maximum stability against heat: 80 to 95 degrees Celsius
- Density: 1.0 to 1.05 grams per cubic centimeter
- Thickness: 1 to 6 mm
- Colors: white, black and gray
Chemical resistance
- Dilute acid: Very good
- Dilute alkalis: Very good
- Oil and grease: Very good
- Fatty hydrocarbons: moderate
- Aromatic hydrocarbons: Weak
- Halogenated hydrocarbons: Weak
- Alcohols: Weak
Vacuum forming mold and its material
Mold design and construction is the most important part of the vacuum forming process.
In this section, our desired design is made as a physical object to be used to form a vacuum to thermoplastics.
It is not possible to shape thermoplastics without a mold, so the mold is the most important part of vacuum forming.
The vacuum forming mold must be designed in a standard way to give us a quality product, otherwise, the mold may lose its stability and shape in the work process, and we will end up with a low-quality and inappropriate product.
There are several important points such as the shape, material of the mold, size and volume of the product in the design and manufacture of the mold that should be considered.
We will further examine this issue.
Mold material
The meaning of material is the material used in making the mold, which is usually aluminum, wood, MDF, clay, resin, etc. used in making the mold.
Aluminum and wood are usually used in Iran.
Aluminium
Aluminum mold is very suitable for large and large productions because it has high resistance and easily dissipates heat in the vacuum forming process.
Due to their high strength, stability and extremely light weight, these molds are very suitable and desirable for wide production for vacuum forming.
These templates are made in two ways, which are:
CNC machine: In this method, the 3D design is first designed with the computer and then it is made and machined by the CNC machine.
Casting: In this method, the mold is made by casting process. This is of little use and is obsolete.
Wood
Designing and making a wooden mold is cheap and easy, and it can be made using many tools and techniques.
Usually, a wooden mold is used to make a prototype of the product.
Using a wooden mold, you can produce prototypes of the product and fix its defects.
Due to its low strength and stability, wood cannot be used for many productions, because it expands and contracts with the cycle of cold and heat, and this action causes it to lose its shape and crack.
Simple carpentry tools and CNC machine can be used to make a wooden mold.
Important points in designing and making molds
In addition to the material of the mold, the requirements and important points in the design should also be taken into account in order to achieve a quality and ideal product.
In this section, we briefly review some basic and essential items.
Angles and slopes
The angles and slopes of the mold should be designed so that during the molding process, the thermoplastic material is well absorbed and distributed over the entire surface of the mold, and the release of the mold is done easily and without problems.
Air vents
Vacuum forming is highly dependent on air flow to draw the heated plastic into the mold through embedded holes.
It is very simple; The more suitable the air flow and air discharge conditions are, the more successful the vacuum forming process will be.
With this in mind, any mold made should have air vents to allow air to escape between the plastic sheet and the mold.
These holes should be created on the mold to create a channel for air evacuation by the vacuum pump.
Any place on the mold that has significant depressions and grooves will need 1-2 drain holes.
These holes are responsible for attracting the plastic sheet to the mold and will not be visible on the final product.
The positive and negative aspects of the format
Basically, there are two types of vacuum forming molds: male (positive) and female (negative).
See the following figures:
Several factors affect the selection of the right vacuum forming template, pay attention to the useful tips that we provide below.
The top surface of a vacuum part (the part not in contact with the mold) is undoubtedly a better finished surface because it cannot pick up impurities such as dust from the mold.
This factor alone can determine whether a male or female frame is needed.
Often times, making a male mold is easier and more suitable for parts that have a lot of depth.
On the other hand, a material mold is suitable for shaping parts such as disposable containers or trays.
Therefore, the surface that we want to be of better quality should be placed in the outer part of the mold and not in contact with the mold.
The figure below shows a combined male and female mold for shell packaging:
Undercut
Undercut is a depression or protrusion that prevents the part from being removed from the mold.
There are two types of undercoat, internal and external, and it is rarely seen in vacuum forming molds.
Things that the template designer should pay attention to:
- Undercuts should be avoided as much as possible to make the production process easy and low-cost.
- If possible, remove the undercut with female or male design methods or cover it with other materials so that there is no defect in the shape of the piece.
- If this is not possible, advanced templates must be used and this will involve a lot of costs.
Vacuum forming devices
In general, vacuum forming machines are divided into two categories, semi-automatic and automatic, each of which has its own functions and features.
Semi-automatic devices
These devices are made in small sizes.
The way these machines work is satisfactory, but they are not suitable for mass production because the speed of production and shaping in these machines is low and they need an operator to do the necessary work.
Semi-automatic devices are fed by plastic sheets and have parts such as mold, heater, clamp and vacuum pump.
The working steps in these devices are as follows:
- First, the aluminum mold is closed in the band mold section
- Then the plastic sheet is placed on the device.
- Then Hitler is put on the electricity by the operator to see the heat sheet.
- After heating, the mold that is under the sheet rises up and sticks to the sheet, then vacuum forming is done to evacuate the air between the mold and the sheet.
- After forming the sheet and cooling, the formed part is separated from the mold.
Automatic devices
These devices are made in large sizes.
Automatic machines are suitable for high production because the speed of production and shaping in these machines is very high. In these machines, the operator has less involvement in the production process and most of the work is done by the machine.
These devices are fed with plastic rolls and have mold parts, heaters, coolers, vacuum pumps, cutters and plastic roll holders.
The working steps in these devices are as follows:
- First, the template is closed in the template section.
- Then the plastic roll is placed in the roll holder.
- The next steps are performed by the machine, which includes heating, shaping, cooling and cutting the formed part.
Basic production requirements
For the production of vacuum forming packaging, necessary materials such as plastic materials, aluminum mold and vacuum device are needed.
Plastic materials
Plastic materials used in vacuum forming are thermoplastics, thermoplastics become soft and flexible with heat and are easily moldable.
Thermoplastics include PVC, PET, HP and ABS materials.
Aluminum mold
The vacuum forming mold is first designed with 3D computer software and then made with a machining or CNC machine.
The mold is closed on the machine and used to shape thermoplastics.
The molds are made of aluminum to easily dissipate the heat of the vacuum forming process, and their weight is also very low.
The molds in this process are both male and female, in some vacuum packaging, male mold and in some, female mold, as well as in folding packaging, both types are used.
Vacuum forming machine
The vacuum forming mold is first designed with 3D computer software and then made with a machining or CNC machine.
The mold is closed on the machine and used to shape thermoplastics.
The molds are made of aluminum to easily dissipate the heat of the vacuum forming process, and their weight is also very low.
The molds in this process are both male and female, in some vacuum packaging, male mold and in some, female mold, as well as in folding packaging, both types are used.
Vacuum forming services
Fortunately, vacuum forming services and vacuum packaging industry have reached an acceptable position in our dear country of Iran and today it has very efficient capabilities.
Formanig vacuum services include:
- Blister packaging
- card
- clamshell
- stand
- skin
By God’s grace, Ararat Group has been able to meet the needs of its dear customers and is engaged in providing vacuum forming services in Tehran, the beating heart of Iran.
To order product packaging, please contact us through the available communication channels.
Frequently Asked Questions
Vacuum forming packaging is a packaging method in which shaped and transparent plastic is used to package various products.
The vacuum mold is made of aluminum and is designed according to the desired product and made with a CNC machine. The mold is used in the vacuum forming process to shape the plastic sheet.
Vacuum forming is used to package products such as toys, cosmetics, sweets and chocolates, tools, electronic devices, etc.
Yes, in vacuum forming, there are various seals such as high frequency and press that can ensure the security of the product against manipulation.
Vacuum forming packaging usually uses plastics such as PVC, PET, Hympack and ABS, which are recyclable.
Yes, products with vacuum forming packaging are suitable for international transportation due to their high strength and reduced volume. Also, vacuum forming packaging can protect the product from impact, moisture and transportation risks.
Vacuum forming packaging has the ability to form and adapt to different sizes and shapes. By using molds that are designed according to the required size and shape of the product, it is possible to produce vacuum forming packaging with different dimensions and shapes. For this reason, vacuum forming packaging is known as a reliable and suitable packaging method for products of different sizes and shapes.
Yes, vacuum forming packaging can protect products from impact and mechanical damage. By using this type of packaging, by compressing the product inside the package, the empty space between the product and the package is reduced, which reduces the possibility of product breakage and damage during transportation. However, vacuum forming packaging cannot be used alone as a complete method of protecting products against impact and severe mechanical damage and should be combined with other methods such as the use of protective boxes and sustainable packaging materials.
