By Dianna Brodine, vice president, editorial, Plastics Decorating
As brand owners face mounting pressure to reduce costs and improve sustainability, lightweight packaging has become a key focus across the food and consumer goods industries.
By using less material without compromising performance, manufacturers can lower raw material costs, reduce transportation expenses, and minimize environmental impact. In addition, consumers increasingly favor packaging that is easier to handle and generates less waste, making lightweighting an important strategy for brands seeking to balance sustainability goals with operational and economic advantages.
Enter the 6-ounce TRIM cup from StackTeck, an Ontario-based manufacturer delivering high-performance injection molds and automation systems across the globe.
Reducing Part Weight, Reducing Material Use
This 6-ounce cup, in a size utilized for packaging of single-serve foods such as yogurt, pudding, and applesauce, features several innovations, including StackTeck’s Thin Recess Injection Molding (TRIM) technology, with ultra-thin 0.009” panels that reduced the cup’s weight by 20%.
The cup is molded using PureCycle Technologies’ recycled polypropylene rPP and is decorated with MCC Global IML’s Ultra Gloss/Matt IML labels for high-impact, premium graphics. Together, these technologies provide a more sustainable alternative to conventional virgin polypropylene packaging by reducing material use. The result is a lightweight, high-performance package that is 100% recyclable.
“In-mold labels are one of the most premium decoration options available for rigid plastic packaging,” explained Jordan Robertson, vice president, business development and marketing for StackTeck. “Since both the label and container are made from polypropylene, the entire package is fully recyclable.”
In addition to their high-quality appearance, IML-decorated products are durable and well suited for reuse, extending their life cycle. IML technology also eliminates the need for secondary decorating processes, as the package is fully finished when it leaves the mold. This reduces manufacturing steps, improves efficiency and helps lower the overall carbon footprint.
Overcoming Challenges
Designing and producing the lightweight packaging application wasn’t without its trials. “The ultra-thin wall design required complete balance of fill, structural integrity and dimensional stability,” said Robertson, “so the part was engineered with optimized flow leaders. These challenges were overcome through our expertise in mold design, simulations, automation and process optimization.”
Using recycled polypropylene rPP also added technical difficulty. For this application, PureCycle supplied a compounded PureFive Choice™ resin grade containing 30% post-consumer recycled content. The material was visbroken to achieve the required melt flow and formulated with an impact modifier to provide durability and performance.
The result is a lightweight rPP package that delivers significant material savings without compromising functionality, appearance or recyclability – and proves circularity is possible in a food-contact container.
Designed for Recyclability
Intentional design and production choices by StackTeck resulted in a 6-ounce cup that was designed for recyclability from the start.
First, the part weight was reduced using TRIM technology, resulting in less material usage right from the start. Then, in-mold labels were chosen to provide a premium appearance and simplify decision-making on the part of the consumer – because both the label and container are made from similar PP-based materials, consumers easily can toss the cup into the recycling bin rather than deciding if the package complies with recycling guidelines.
Now that’s what we call smart packaging.