TASK

RESEARCH 5 - MOLDS

As my packaging will be created from pulp I have done further research on that. Molded pulp, also named Moulded pulp or Molded Fibre, is a packaging material, typically made from recycled paper board and/or newsprint. Molded pulp is often considered a sustainable packaging material,as defined by the Sustainable Packaging Coalition (is an industry working group dedicated to a more robust environmental vision for packaging), since it is produced from recycled materials, and can be recycled again after its useful life-cycle.

 

Several types of molded pulp can be manufactured by several processes.

Type-1: Thick-Wall

These products usually have wall thicknesses of 3/16" to 1/2" and are used primarily for support packaging applications. Thick Wall is also commonly referred to as Slush Molded. The surfaces are very rough on one side and moderately smooth on the opposite side. Product definition is moderate due to the use of relatively inexpensive single-pass molds and the use of mixed recovered paper and kraft paper slurries. Typical uses are for edge protection, heavy item packaging, auto replacement parts, molded pulp pallet trays etc.

Type-2: Transfer Molded

A McDonald's spray-molded vacuum-formed cup carrier. The open slits are punched out of the carrier following the drying process.

Transfer molded products are usually thin walled, 1/16" to 3/16", and are the most prevalent type in use today. The process uses vacuum forming and take-off or transfer molds, where the mold is an extremely fine wire mesh in the shape of the upper/exposed surface. The fibrous slurries are frequently made up of a high percentage or entirely of recycled newspaper, which produces a relatively smooth surface on one side and a fairly smooth surface on the opposite side with good accuracy and definition.

Prior to the molding process, the mesh is mated with a vacuum chamber that draws water through the mesh into the chamber, with the mesh mold suspended above a liquid return pool. The fibrous slurry is sprayed from below onto the mold, and the vacuum draws the slurry tightly against the mesh, filling all gaps and spaces. When airflow through the mesh has been sufficiently blocked, the excess slurry falls into the return pool for recycling, and the mold advances onward to the drying process, following by separation of the mesh mold from the dried fiber plating.

Typical uses of transfer molded products are for packaging electronic equipment, cellular phones and other household and hardware items. Very high capacity, high-speed transfer molding equipment is used to produce drink trays,cup carries ,wine shippers ,egg cartons, egg trays, pulp bedpan liners, pulpurinals, fruit trays, slipper pans, commode pans, end caps, etc.

Type-3: Thermoformed Fiber

This newest form of molded pulp is the highest quality of thin walled products available today. The process uses "Cure-In-The-Mold" technology which produces well defined, smooth surfaced molded pulp products. After being formed, the product is captured in heated forming molds which presses and densifies the molded products. They are accurately formed and have the appearance of plastic material. The products are ejected from the heated molds in their finished state as opposed to being dried in a heated oven. Typical uses for this type are for point-of- purchase packaging and those applications where high definition and appearance are of prime importance.

Type-4: Processed

This type of molded pulp product is that which has undergone some kind of secondary processing which is generally different than or in addition to, the basic production procedure. This could apply to any of the first three types. Secondary processing could be coating, printing, hot-pressing, die-cutting, trimming or manufactured using colors or special slurry additives. Uses are for many kinds of custom applications.

MOLDS

After group work everyone said that the idea of molding  is really good one  - which affirmed me even more in my idea! Also conversation with Andy with regards to transportation allowed me think about the best solution. Easily transportable?? not sure, I think it needs to closed up.

I have been thinking about the mold and perhaps that could be an insert inside the box. It will be firm and it will keep the products in tact  - and as it is a box it will also work better with regards to transportation...
As I do not have mycelium I have been experimenting with papier mache to create it:
  

  

I have looked back at my doodles and thought of another idea - follow on my molds - I wonder if  a  box entirely molded apart from the top part, which will close and open the box, will work??
And here it is:

 

 as it is a mini box it was quite tricky to create precision, but hopefully when it comes to larger scale it will be easier.

Unfortunately I can not find company in UK that would work with mycelium....

PACKAGING NETS AND TESTS - TASK THREE

TASK THREE

This packaging would be suitable for LIGHT product  pencils, pens and crayons, square light items, etc. This packaging is designed to be hanged on a display line.

This packaging might need reconsideration with regards to opening and closing.

So the improvement of this packaging would  entirely depend on its content. The heavy items wouldn't be suitable because the bottom of that box is not structurally design to hold the weight of a heavy item.

Depending on fragility of a product this packaging might need extra support insert - to hold and cushion the product in place.

MY PACKAGING  - ANSWERS:

1) because of my aim  - packaging without glue - there will be no need for glue. Hopefully I will design it in a way that the tabs will help with closures and creating handle for this packaging.

2) as of my previous research on material used for my packaging I have reconsidered using biodegradable material purely because of my idea of reusing my packaging. It will be molded pulp material - made of recyclable paper or fibers. And NO glue used.

Ideally I  would really like my packaging to be made of mycelium but so far I haven't found a manufacturer who would produce so. Very effective material!

I have researched about it and found that Dell Company plans a pilot to grow their own packaging from mycelium! The technology involves using agricultural waste like cotton seed, wood fiber and buckwheat hulls,which are placed in a mould and inoculated with mushroom spores, so it becomes the root structure of the mushroom and grows into the shape of the mold. 

Dell's procurement director Oliver Campbell explained: "It's just as rigid and protective to your desirable gadget as the old materials. We've tested the mushroom cushioning extensively in the lab to ensure it meets our same high standards to safely protect our products during shipment, and it passed like a champ". (http://www.wired.co.uk/news/archive/2011-04/7/dell-plans-mushroom-based-packaging)

 

Fantastic!