In the current global economic environment, manufacturers urgently need to address the challenges brought by the rapidly changing and evolving market, while also advancing stronger sustainability practices. A leading North American sustainable packaging handle manufacturer (whose products are widely used in the food, beverage, and consumer goods industries) requires a heavy-duty, high-performance injection molding solution to support the mass production of plastic handles made from 100% recyclable HDPE using multi-cavity molds. Husky's Hylectric injection molding system has brought significant ongoing improvements to this customer.

Challenge

The challenge is to provide a solution that can not only manage stringent production, productivity, and quality requirements but also efficiently handle recyclable materials, aligning with the principles of the circular economy.

Solution

To assist the customer in producing can-packaged beverage packaging handles, Husky recommended its high-performance Hylectric machine platform. The unique Reflex platen of the Hylectric injection molding machine provides uniform mold clamping force distribution, resulting in superior part quality, reduced scrap, and extended mold life. The system was designed with optimized screw geometry for more efficient processing of recyclable resins. The melt flow transfer components, including the screw, barrel, and non-return valve, are made from specialized high-wear materials to improve recyclable material processing and extend equipment life.

Hylectric - The Ultimate Packaging Injection Molding System

Results

Husky's Hylectric system has delivered several significant ongoing improvements to the customer in terms of performance, productivity, and sustainability. Enhanced by Husky's hot runner systems optimized for processing recyclable resins, the Hylectric machines have demonstrated excellent performance, part quality, and reliable results during long-term operation. By using recyclable materials, the manufacturer has significantly reduced its carbon footprint - greenhouse gas emissions have decreased by 78% compared to native HDPE, energy consumption has decreased by 90%, leading to reduced production costs, and petroleum usage has been reduced by 100%. Additionally, the handles made from 100% recyclable materials can be recycled for future conversion into new handles or other products; by gradually phasing out virgin materials, they can significantly reduce component costs.