Husky Technologies application spotlight: transforming the cutlery market with sustainable innovation

Project Overview

PlantSwitch, an ambitious startup based out of the US that was aiming to replace petroleum-based single-use plastic with plant-based alternatives, contacted machine maker Husky Technologies in 2022 to learn more about injection moulding options for a line of innovative bio-plastic cutlery.

The challenge lay in overcoming a lack of experience in both the market and injection moulding techniques and processes, as moulding with bioresin typically requires vast processing knowledge to successfully produce a high-quality part.

Developing a winning business case PlantSwitch understood that working with a proven and experienced injection moulding equipment solutions provider would be a key component in enabling their vision to be a leading bioresin based cutlery manufacturer and supplier.

Collaborating closely with PlantSwitch leadership, Husky worked with their team to develop a plan that included lab trials along with a number of business cases that helped PlantSwitch to understand the full scope of the investment that would be required for this project.

“Understanding that the market is shifting due to various legislative requirements around single use plastic, along with a consumer shift towards a more environmentally friendly solution, we saw an opportunity to leverage our bioresin technology and focus our efforts on providing the highest-quality home compostable resin. Utilising this resin, we developed a project in collaboration with Husky to produce industry-leading compostable cutlery,” said Dillon Baxter, CEO and Co-founder of PlantSwitch.

To ensure the effectiveness of their new, plant-based resin, PlantSwitch worked with Husky on testing to better understand how this material behaves in an injection process. Following robust lab and analysis trials, the resin showed extremely promising results using Husky hot runner technology. Coupled with a growing consumer market for environmentally friendly home-compostable products, the outcomes prompted a revival of the original cutlery production concept and the development of new cutlery designs.

The Husky team was able to build a new business case, define the necessary cavitation, and recommend an integrated solution best suited for the application: a Husky Hylectric packaging moulding system with a specialised mould utilising UltraMelt, Husky’s innovative hot runner technology for bioresin melt delivery.

A sustainable future

Armed with the Husky Hylectric system and UltraMelt hot runner, PlantSwitch soon secured a significant order from a leading American supermarket chain for a line of innovative, plant-based cutlery, positioning the company as a vertically integrated producer.

But PlantSwitch’s potential does not stop there. The company is now exploring the production of compostable coffee pods, showcasing their commitment to sustainable and environmentally friendly packaging alternatives.

“PlantSwitch stands at the forefront of the eco-conscious movement, and our collaboration with Husky has paved the way for a transformative impact, proving that when done right it’s possible for sustainability and economic viability to go hand-in-hand. Together, we’re not just creating products; we’re shaping a greener, more resilient future,” Baxter said.

Husky’s holistic approach to injection moulding

Husky is a dedicated single-source provider, seamlessly integrating world-class injection moulding systems with a wealth of expertise, comprehensive guidance, and a holistic perspective to ensure customers’ success.

It provides:

Husky’s Hylectric systems

To handle the sensitivity of injection moulding bioresins, Husky systems are adapted to meet the melt preparation needs and requirements of this specific raw material. The machine extruder and respective melt stream delivery components are modified to enable high part quality and a wide process window.

In addition, Hylectric systems are designed to support aggressive cycle times for a wide range of applications and 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-topart consistency and quality.

Superior tonnage distribution helps to reduce clamping force and mould wear, as well as ensuring high part quality on long term runs. This, combined with wide tie-bar spacing, large platens and a stiff clamp base, make Hylectric ideally equipped to run heavy, high cavitation moulds at aggressive cycle times – making it the perfect fit to cutlery moulding.

The latest generation Hylectric systems also include 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 systems from 120-1,200 tonnes with a broad selection of injection units. Longer versions of the clamping unit are available for large shut-height tools.

Husky’s Ultramelt hot runner system

Husky’s UltraMelt technology is a premium melt-delivery approach for applications requiring excellent process and thermal control with minimal effect on resin chemistry.

Utilising dozens of different test manifolds, UltraMelt was designed to help users produce small parts with materials more sensitive to temperature and chemical reaction. UltraMelt features specifically designed components made from aerospace grade materials to preserve the sensitive chemistry of bioresin and minimise corrosion and other challenges. Configurations are available with a variety of gate methods, nozzle sizes, and actuation styles for low and high cavitation molds.

The hot runner manifold was designed for balanced melt supply to each mould cavity with careful consideration to both pressure and melt volume. A valve gate nozzle was used to maintain best-in-class gate quality and extended mould life. In addition, all components were designed with cost of ownership in mind, as well as extended maintenance intervals enabling maximum service life for years to come.

For further information contact: https://www.husky.co/en/contact/

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