TECHNOLOGY AND PRODUCTION PROCESS FOR PLASTIC PACKAGING

Production at Maropak is carried out on the basis of a structured and fully controlled technological process, the aim of which is to ensure consistent parameters, production stability, high-quality products and on-time deliveries.

Every stage – from the receipt of raw materials to the finished product – is subject to systematic quality control in accordance with applicable production procedures and certified management systems.

As a manufacturer of plastic packaging, we use technologies that enable us to produce bottles and containers for the cosmetics, chemicals, pharmaceuticals and food industries.

Measuring a red plastic jar with a caliper, with the packaging model on screen

procesy produkcyjne

Our production processes primarily include:

BLOW MOULDING

INJECTION MOULDING

INJECTION STRETCH BLOW MOULDING (ISBM)

The choice of production technology depends on the type of packaging, product requirements, material and the expected technical parameters.

Blow moulding

Production of plastic bottles and containers

Blow moulding is one of the most widely used technologies in the production of plastic packaging. This method enables the efficient production of bottles and containers of various shapes and capacities

This technology is primarily used for the production of:

cosmetic bottles;

packaging for household cleaning products;

containers for the food industry;

technical and industrial packaging;

packaging used in gardening.

The materials most commonly used in this process are:

HDPE – high-density polyethylene;
LDPE – low-density polyethylene;
PP – polypropylene;
PET;
PET-G;
PCR – recycled plastics.

Głowice maszyny do formowania rozdmuchowego podczas produkcji butelek

How does the blow moulding process work?

The production of packaging using blow moulding technology begins with the plasticisation of plastic granules at a high temperature. The material is then extruded in the form of a plastic tube.

In the next stage, the plastic tube is enclosed in a precise, water-cooled mould, and air is blown into it. This causes the material to expand and conform precisely to the shape of the mould.

Once the material has cooled, the finished plastic bottle or container is formed.

Advantages of blow moulding technology

This technology enables:

the production of bottles and containers in a variety of shapes;
the manufacture of packaging with handles;
high repeatability of production parameters;
the use of recycled materials.

This means that packaging production can be precisely tailored to the requirements of various industrial sectors.

Injection moulding

Precise manufacturing of plastic components

Injection moulding is one of the most precise technologies used in plastics processing. This technology enables the production of components with very high dimensional accuracy.

At Maropak, this method is primarily used for the production of:

closures and caps;

packaging components;

technical components.

The process involves injecting molten plastic into the mould cavity under high pressure. Once cooled, the material hardens, taking on the exact shape of the mould.

Advantages of injection moulding

Injection moulding offers:

very high dimensional accuracy;
the ability to produce components with complex geometries;
high production efficiency;
short production cycle times.

It is possible to produce multiple components simultaneously in a single production cycle, which enables high-volume production to be carried out efficiently.

An additional advantage is the ability to reuse surplus material, which helps to optimise the production process.

Operator at an injection moulding machine in the Maropak production hall

ISBM injection stretch blow moulding machine at the Maropak plant

Injection-stretch blow moulding (ISBM)

Production of PET bottles

ISBM technology is primarily used for the production of lightweight, durable PET packaging with high transparency.

This method is used, amongst other things, in the production of:

PET bottles;

cosmetics packaging;

packaging for the food industry.

The materials most commonly used in this process are:

PET – polyethylene terephthalate;
R-PET – recycled PET.

Stages of the ISBM process

The ISBM production process consists of two main stages.

In the first stage, a so-called preform is produced using the injection moulding method. This enables the bottle neck and thread to be formed with a high degree of precision.

In the second stage, the preform is heated to the correct temperature and then stretched and blown in a mould to achieve the final shape of the bottle.

The process can be carried out using a single-stage or two-stage system, depending on the production technology.

Advantages of ISBM technology

This technology enables:

the production of lightweight PET bottles;
high transparency in packaging;
very good consistency of parameters;
optimisation of material consumption.

As a result, this method is widely used in the production of packaging for the food, cosmetics and chemical industries.

Production Quality Control

Packaging production at MAROPAK is carried out in accordance with the requirements of the ISO 9001, ISO 13485 and FSSC 22000 standards, ensuring the high quality and safety of every product.

Inspection of raw materials and components

Verification of certificates, declarations of conformity and the properties of the granules prior to their release for production.

VERIFICATION OF PRODUCT REQUIREMENTS

Analysis of technical documentation and customer requirements, confirmation of compliance with specifications.

production preparation and approval

Inspection of moulds and tooling, setting of process parameters, approval of the first parts.

In-process supervision

Ongoing dimensional and weight measurements, functional and leak tests, batch traceability.

Finished product inspection

Visual assessment, final measurements, verification of compliance with customer requirements and standards.

Product traceability and safety

Full batch traceability, risk analysis and measures to ensure packaging safety.

Product specifications are monitored at every stage of production, ensuring compliance with customer requirements and applicable food quality and safety standards.

Each batch of products undergoes a final inspection, which includes an assessment of:

technical parameters;

workmanship quality;

compliance with customer requirements.

A product is only released for dispatch once it has been confirmed that it meets all the specified quality criteria.

Measuring a plastic sample during quality control, with bottles and a laptop showing results

White plastic bottles on the production line

Consistency as a key value for the customer

For business customers, it is not only the quality of a single batch that is crucial, but also its complete consistency over the long term.

For this reason, the production process at Maropak has been designed to enable:

the maintenance of consistent technical parameters;

consistency between production batches across successive production cycles.

The stability of the production process has a direct impact on customers’ operational safety and the continuity of their production.

Transparency and readiness for audits

Maropak operates on the basis of certified quality and safety management systems.

Production processes are documented and subject to regular reviews. The company is prepared to work with clients who require quality audits and compliance with specific industry standards.