Technology
Ecozema® products are made from a wide range of materials. Therefore, also production technologies are quite diverse among each other.
Injection molding: thanks to this process, it is possible to transform biopolymers like Mater-Bi® and Ingeo™ P.L.A., into complex manufactured products with a minimum thickness slightly below 1 mm. Firstly, the polymer is melted and then injected into a mold. Then, after the material has been cooled, the mold can be opened and the product extracted from it, generally without any further interventions.Pros: high dimensional precision, it is possible to create products with complex shapes, fair productivity.Cons: high initial investment cost (mold), it is not possible to work with quite thin biopolymers.This is the technology used to make Ecozema® cutlery.
Cardboard forming: this is the latest transformation technology introduced in our company. With this process it is possible to obtain cardboard containers that are perfectly liquid or fat-proof as they are formed without any gluing or jointing. We start from a reel, with or without coating, we go through an initial phase of fiber yielding and then move on to die-cutting. The blank obtained is then inserted into a forming mold where, due to the effect of pressure and temperature, the cardboard deforms and remains in the desired geometry. Pros: high productivity, good dimensional precision, perfect seal for liquids and fats, possibility of customizing with printing Cons: mold necessary for each individual format, special cardboard required, creases in the cardboard cannot be eliminated in the fold areas.
Thermoforming: first, the polymer is extruded into a sheet which then is vacuum-formed into a mold, heated at high temperature in order to stretch it and shape it as desired. Based on the machine, the product is separated from the sheet either in a single step during the forming or a second step. Thanks to stretching, the material can become very thin, up to a 1/10 mm.Pros: high productivity, light products thanks to obtainable low thicknesses.Cons: high initial investment cost (mold).
Molded fiber: with this process, cellulose fibers are mixed with water resulting in a pulp, where additives may be added. The mix is subsequently inserted into a mold where it is shaped. At this stage, the piece is still full of humidity so it is moved onto another mold where it is dried and trimmed.
Papermaking: it is the process by which various products from the Ecozema range are made including cardboard cups, salad bowls, take-away containers or trays. The process starts from a blank which is then folded and welded in various steps until the finished product is obtained. Pros: high productivity, good dimensional precision, possibility of customizing with printing, good flexibility in formats, for some formats liquid and fat sealing