Application Spotlight: Sustainable Paint Pails Boost Production and Reduce CO2 Emissions by 65%

Opportunity

Husky’s customer, a leading paint pail producer in Latin America, sought a more sustainable molding approach without compromising on quality or output. The company required a comprehensive solution that could deliver on three key objectives:

• Transition to a high percentage (60%) of post-consumer recycled (PCR) content in their pails to minimize their environmental footprint
• Maintain the production of top-quality pails with IML (in-mold label) decoration, meeting all performance standards for paint containers
• Achieve high-volume, continuous production
  

SOLUTION 

Husky suggested a comprehensive solution centered around its high-performance platform, which included a Hylectric 4.0™ machine and hot runner system. Designed for exceptional performance and energy efficiency, Hylectric 4.0™ machines have optimized melt delivery components that are ideal for PCR pail production. Husky’s hot runners, meanwhile, optimize the melt stream delivery process, ensuring consistent material flow for the production high quality IML pails that meet all performance requirements.

Husky’s customer opted for two Husky H300 RS80/70 Hylectric 4.0™ machines, which support cycle times of ~11s for 2-cavity IML systems producing 5L paint pails produced from a resin blend containing ~60% PCR and achieving a total production volume of approximately 10 million pails per year. The Hylectric 4.0™ machines and hot runners works in tandem to yield a high-performance production cell capable of continuous IML pail production while achieving exceptional overall equipment effectiveness. In addition, Husky’s Ultra hot runner technology is sustainable-resin ready, with product configurations that are optimized for PCR applications.

RESULTS

This innovative solution has yielded significant benefits for this producer, including:

• Pails manufactured with 60% PCR content
  
• An up to 65% reduction in CO2 emissions
  
• A substantial reduction in energy consumption as r-PP pellets require only 12% of the energy needed to process virgin resin

What Are Hylectric Injection Molding Machines?  

Hylectric 4.0™ injection molding machines are designed to support aggressive cycle times for a wide range of applications like thinwall packaging, pails, closures, and medical devices. 

Hylectric 4.0™machines are equipped with Husky’s distinctive three-platen clamping unit. The Reflex™ platen is designed to enable uniform clamping force distribution across the entire molding surface, for part-to-part consistency and quality. 

Superior tonnage distribution helps to reduce clamping force and mold wear. This combined with wide tie-bar spacing, large platens, and a stiff clamp base, makes Hylectric 4.0™ ideally equipped to run heavy, multi-cavity molds that would typically require larger conventional machines. 

The latest generation Hylectric 4.0 includes all of the standard features and configurations of previous generations, with capabilities to enhance connectivity, control, energy management, and streamline operator experience. The result offers superior levels of productivity, versatility, and ease of use. 

To meet growing demands for performance flexibility, Husky offers Hylectric 4.0™ machines from 120 to 1200 metric tons with a broad selection of injection units. Longer versions of the clamping unit are available for large shut-height tools.

NEXT STEPS

Speak with a Husky packaging expert to learn how our latest technologies can address your packaging needs.