PCR Spray Cap Assembly

Mold-Masters Enables Global Consumer Goods Brand to Successfully Utilize PCR in High-Volume Spray Head Assembly

Companies continue to explore applications suitable for utilizing Post-Consumer Recycled (PCR) materials as part of their sustainability initiatives. Utilizing PCR helps extend the useful life of materials and can help lower carbon emissions compared to the production of new virgin resin. However, injection molding PCR comes with its own set of challenges. As PCR is a blend of material coming from a variety of sources, the quality of the material can be inconsistent. Therefore, processing parameters to vary significantly from batch to batch. This can limit their suitability for certain applications and make molders hesitant to use them.

A body spray head assembly, made up of 4 components, is another recent successful application that has been injection molded with PCR. This PP PCR material was 95% post-consumer material sourced from pre-sorted municipal plastic packaging waste. The components ranged in weight from 1.02g to 4.96g. As this component was being used for the product of a global consumer goods brand with huge volumes, the customer had strict requirements for part quality and ultimately selected a Mold-Masters Master-Series hot runner system as it offered good process stability to ensure continuous and stable production to meet the demand.

As a result of enabling the use of PCR in this application, it's estimated that this will save 229 tons of virgin plastic and reduce carbon emissions by 520 tons annually (based on anticipated annual production volumes).

Mold-Masters has been processing PCR successfully for over a decade. Our standard hot runner designs incorporate a range of technologies and are often optimized to overcome the processing limitations presented by PCR materials. This makes Mold-Masters hot runner systems well suited for processing PCR and Bio-Resin materials.

Mold-Masters’ proven PCR and Bio-Resin processing solutions are well suited to packaging, consumer good and many other applications. Shape What Matters For Tomorrow with Mold-Masters.