Inpak is an engineering company specialised in multi-station thermoforming machines, suitable for high volume mass plastic packaging production. In this process, plastic sheet is heated as it passes through the heater trays. The sheet reaches a thermoformable temperature and arrives to the forming station. Here, pressure air is applied, causing the sheet to extend and conform to the shape of the mold. To further enhance the quality of the end-products, plug assist systems may be employed to provide additional support during the forming process. To remove any trapped air inside the mold, vacuum is applied. Next, product edges are defined in the cutting station by using the steel rule die blades. Finally, the finished products are stacked in the stacker unit according to desired quantities and are then delivered on a conveyor to the packers.
Inpak machines can convert all thermoformable materials like PET, CPET, PP, PS, OPS, PLA etc.
The proccessable sheet thickness range is 0,15 mm – 1,5 mm
Maximum upward and downward formable depth is 140 mm
TS-800: Maximum mould dimensions are 800 mm x 580 mm, minimum mould dimensions are 360 mm x 400 mm.
TS-850: Maximum mould dimensions are 850 mm x 650 mm, minimum mould dimensions are 360 mm x 400 mm.
TS-1000: Maximum mould dimensions are 1000 mm x 750 mm, minimum mould dimensions are 500 mm x 480 mm.
Sheet width is equal to mould width plus 40mm.
Considering maximum mould widths among our models, maximum sheet widths are 840 mm for TS-800, 890 mm for TS-850 and 1040 mm for TS-1000
The clamping forces for forming stations in TS-800 and TS-850 are 50 tonnes, whereas in TS-1000, it is increased to 60 tonnes. Similarly, the cutting station clamping forces for TS-800 and TS-850 are 60 tonnes, while in TS-1000, it is further increased to 80 tonnes. Additionally, in the TSR-800 model, which features in-mold cutting, the clamping force for the forming station is 80 tonnes.
A variety of kitchenware and takeaway packaging including lids, plates, containers, hinged containers, meal trays and also seeding trays for agriculture.
The process of changing complete 3-station mould sets typically takes between 35 and 45 minutes. However, if a hole punching tool is involved, the entire change-over time may extend to approximately 75 minutes.
The initial thermoforming machine was built in 2006 and has remained operational ever since. Therefore, it can be regarded as having been in active use for over 17 years, considering the present timeframe.
Providing a variety of configurations is a key factor in ensuring repeat orders and customer loyalty together with offering long machine lifetime, fast and effective service, optimal net running time, as well as mold support. For instance, Inpak offers alternative heating control systems for heater trays, optional adjustable lower hole punching and cutting stations, variable out-conveyor configurations, and a wide selection of stacker unit options to enhance product-based production efficiency.
The required installed power depends on the overall machine configuration requirements. However, the actual power consumption during machine operation ranges from 25 to 40 kW/h. An additional 6 to 15 kW/h is needed if a pre-heater cabinet for PP material is used.
The machine is guaranteed for 1 year or 5000 hours whichever comes first, starting from the date the commissioning report was issued. Inpak will ensure production continuity and provide necessary support and assistance.
Inpak machines are trusted by industry partners in 48 countries across six continents, with over 500 machines in operation worldwide. If a customer visit is required, we can arrange a visit accordingly.
As a thermoforming machine supplier, we offer a range of machines with varying features and specifications to meet different customer needs. The cost of our machines depends on factors such as machine size, configuration, and additional options chosen by the customer. To get detailed pricing information and to understand what is included in the price, we recommend reaching out to our sales team. They will be able to provide you with accurate and up-to-date pricing as well as clarify what is included in the package.
Typically, it takes around 5-6 months to receive a machine after placing an order. However, we understand the importance of timely delivery and are actively taking measures to reduce this timeframe to 3-4 months. Our team is constantly working to streamline the production and delivery process to ensure that you receive your machine as quickly as possible.
Inpak machines are designed with several safety precautions in place to ensure a secure working environment for operators and workers. Machines are equipped with safety guards, sensors, and safety systems to minimize potential risks. We ensure that the design and user interface of our machines adhere to the necessary safety standards and regulations.
We conduct in-house mould trials as a standard procedure in collaboration with our sister mold maker company, Euromak, and other mold maker partners. This process involves testing the moulds to ensure their performance and obtaining customer approval on samples before shipping. As a result, we offer machine demonstrations at our factory.
Inpak, founded in 2006, has emerged as the preferred supplier in Turkey, placing customer satisfaction at the forefront, particularly in the areas of food packaging and agricultural seedling trays. Inpak holds a substantial share of Turkey’s export ratio in these industries, making it the key driver of Turkey’s export performance in this sector. Trusted by industry partners in 48 countries across six continents, Inpak currently operates over 500 machines globally. The brand is renowned for its unwavering commitment to reliable quality and high-performance machines, solidifying its reputation in the market.
INPAK heating capabilities can work with all thermoformable materials (Bio-based, fossil-based, biodegradable, compostable, recyclable materials). Heater trays construction and heater control configurations are designed with high energy efficiency in mind. In the heaters of the machines, HTS type resistors are used which have internal insulation. That gives more targeted radiation effect which achieves 30% energy saving than conventional heaters.
TS-800 and TS-850 thermoforming machines are equipped with 12 line of ceramic heaters, while TS-1000 has 15 lines of ceramic heaters in TS-1000. One of the objectives we have is to ensure getting visually appealing packagings at their best quality so, alternative heater control systems are also offered according to needs.
Adequate water flow at the necessary temperature level is essential for the proper functioning of molds, transport chain rails, and the heating-cooling plate located between the main cutting press and the heated cutting blades. To maintain the required cooled water, an external open-system chiller unit must be utilized. The capacity of the chiller unit varies depending on the specific machine models. Inpak machines monitor the cooling water flow rate to ensure proper circulation within the machine plumbing.
Inpak machines are equipped with B&R Industrial PC’s as their hardware components. The human machine interface (HMI) is operated through our self-developed software which is developed for these PCs.
Once specific mould settings are adjusted, they can be saved as a recipe and easily reloaded at a later time. This system significantly reduces the time required for tool adjustment during mold changes. Additionally, the Human Machine Interface (HMI) has been continuously improved based on customer feedback, resulting in a user-friendly interface that is both easy to learn and operate.
Inpak machines incorporate load cells in their forming and cutting stations to precisely measure and monitor the applied force when the molds are closed. By utilizing load cells, the machine can ensure that the clamping forces remains within the set parameters, thereby providing self-protection for both the machine and the molds.
The mould change-over process is designed to be fast, incorporating guiding and locking systems. Inpak highly recommends the use of specially designed mould change-over trolley which ensures ergonomic work throughout the process.
If the plastic sheet with an inline extruder is not being used, hydraulic cylinders are used to lift plastic sheet rolls onto the unwinder chases. This choice of cylinders is preferred due to their superior load-bearing capabilities compared to pneumatic systems. Subsequently, a motorised unwinder mechanism is activated, allowing the sheet to be released simultaneously with the speed of the machine’s transport chain. This mechanism also ensures that the sheet does not shift to the left or right.
The choice of mould constructions relies on the specific requirements of the product design as well as the project budget. Inpak machines are designed to accommodate plug assist and clamp frame moulds, enhancing their functionality. These machines also feature systems that support product ejection mechanisms within the mould. For optimal performance, fast cooling and lightweighting, aluminum is commonly preferred for the general construction of the mould. The counterside plate of the blades and blades’s bases are made from steel to ensure durability. Additionally, platens and cavity inserts are often coated to enhance their longevity.
To begin with, we take measures to prevent sheet does not shift to the left or right during the process. Proper clamping forces are essential to achieve homogeneous material distribution. However, the key requirements are addressed within the mould itself. Leak gaskets can be employed around each cavity and the mould plates to ensure a tight seal. Additionally, the forming process can be effectively managed using servo plug assist, which offers precise control over the position and timing, while also utilizing applied forming air.
Steel rule die cutting blades are used in the cutting station to cut the edges of the product. The die, a thin flat plate highly recommended to be made of metal, contains sharp embedded blades for cutting itself.
The stacker unit offered by Inpak includes several options for different stacking needs. The standard is conventional sweeper, which sweeps stacked and counted products from the stacker upper frame walls towards the conveyor. The servodriven A-B Stacker is an alternative mechanism that allows for AB stacking within the upstacker frame walls, using servo motors to drive the product lines and transfer them onto the conveyor. The Robot Stacker is a versatile option with multiple working modes, suitable for A-B stacking and accommodating short or small products. The Lid Robot Stacker is specifically designed for round cutting geometries and enables better stacking capabilities for taller stacks. Finally, the Down Stacker is ideal for stacking large and thin products, which can be challenging to hold within the upstacker frame walls.
Once the end-products have been separated from the plastic sheet web, the remaining material on the sheet is referred to as recyclable scrap. This scrap is collected in a scrap winder unit. In cases where an inline side-grinder is utilized after the thermoforming process, Inpak also provides a scrap rotator system to direct the scrap towards the grinder.
Inpak places a high priority on engineering for enhanced reliability and extended lifetimes. To achieve this goal, life cycle engineering is implemented to maximize the lifespan of each component, and parts are designed to fulfill this objective. The company utilizes advanced software tools to model and analyze systems, which are then followed by prototyping and rigorous testing phases. Only after extensive test runs and thorough evaluations does Inpak proceed with the launch of new machine lines or updates.
We use HTS type resistors with internal insulation in our heater trays for targeted radiation and 30% energy savings compared to conventional heaters. The trays are positioned close to the plastic film, reducing temperature settings and improving energy efficiency. They are well-insulated to minimize heat loss to the surroundings. Additionally, our machines feature a regenerative servo drive system that captures and redistributes braking energy, maximizing efficiency.
Inpak has robust quality control and quality assurance processes in place throughout the manufacturing stages. Continuous quality monitoring and inspections are conducted to ensure that the highest standards are maintained.
Inpak technicians will install and commission the machine at the buyer’s factory without any additional charges. The customer is responsible for arranging and covering the costs of full pension hotel reservation, round-trip flight tickets, and all transportation. Air, water and main electric connections to the machine should be ready before arrival of Inpak technicians. Then, machine start-up takes 2 days maximum and additional 3 days is spent for training on HMI and mould change-over.
We maintain a large stock area with a high availability of parts. One of our primary performance indicators is ensuring that requested parts are delivered from the factory within 24 hours of receiving the order.
We provide all the necessary technical features required for achieving the highest cycle speeds, accompanied by a user-focused HMI (Human-Machine Interface). Our goal is to eliminate complexity that could hinder operational availability. By combining optimal engineering solutions and efficient resource management, we ensure continuous production and cost advantages, allowing us to offer competitive pricing to our customers.
We engineer for reliability over longer lifetimes, prioritizing increased running availability. Customer experience and satisfaction are at the forefront at Inpak, as repeat orders drive our business sustainability and growth. Therefore, in addition to designing Inpak machines for low maintenance, we also provide the possibility of remote access to them. With remote access capabilities, we can efficiently monitor and troubleshoot the machines, reducing downtime and minimizing the need for on-site servicing. Furthermore, our maintenance scheme includes periodic visual inspections and manual lubrication in specific sections, ensuring optimal performance and minimizing the need for additional servicing. If there is a requirement for on-site servicing, Inpak can promptly arrange a visit to ensure the smooth continuity of production.
Inpak is responsible for the installation and commissioning of the machines. We provide training on the fundamental usage of the machines during the start-up stages and provide ongoing production consultancy. Additionally, we welcome customers’ operators to receive additional training at our factory, where they can observe various mould trials.