Oct 11, 2021

Overcoming the challenges of "high definition plastic"

Roctool's technology enables high-definition surface quality for injected plastics, which traditionally have been used in the consumer electronics and automotive markets.
Elisabeth Skoda

The company has transferred its expertise to beauty packaging by creating a solution that it says is cost effective, offers premium aesthetics and sustainability credentials.  

Roctool's patented high heat molding technology makes it possible to produce plastic parts with high surface quality, which can avoid secondary operations such as painting or decoration, reduces the thickness of parts by improving the material flow. The technology is used predominantly in plastic injection, blow molding and compression molding. It is suitable for most plastic resins.

The process of material transformation lies between the thermal exchanges created between the mold and the material, and Roctool has developed what it describes as an ultra-fast induction heating process in order to replicate the surface of the mold directly on the injected part.  Roctool technology overcomes several challenges around “high definition plastic”.

For example, a PCR ABS resin molded with Roctool technology can offer a gloss unit (GU) of 85 and texture replication of 98%, compared with a GU of 53 and 45% replication that are possible with conventional molding.

Roctool Beauty Solutions is suitable for all types of make-up, skincare and fragrance packaging solutions (bottles, flexible and rigid tubes, jars and all types of lids and caps.) Depending on the aesthetic or functional purpose of the part, using Roctool’s induction heating technology to control temperature in the mold allows the creation of ultra-thin parts, shiny, matt and textured surfaces, as well as the removal of defects like injection points, weld lines and all other material-flow lines.

By obtaining high surface quality and accurate mold replication, Roctool’s technology eliminates the need for secondary operations with a harmful carbon footprint such as coatings/varnish, paint or films, says Roctool's CEO Mathieu Boulanger.

“Our technology allows no compromise between luxury and sustainability. Today, the two must go hand in hand. As such, we are pushing our research in several areas: with designers from around the world, suppliers of innovative materials, and of course with our customers, whose expectations we share. We are well aware that our industry has entered a new era, a challenge we are committed to overcoming every day.”

Elisabeth Skoda

Editor of Touchpoints magazine, writer for Packaging Europe magazine and design enthusiast!
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