Project Overview
A consumer packaged goods company required high-volume production of food-safe packaging containers with living hinge design. The project demanded FDA compliance, reliable hinge performance, and efficient mass production.
Challenge
The primary challenges included:
- FDA Compliance: Food-contact materials meeting FDA 21 CFR requirements
- Living Hinge Design: Integral hinge must withstand 10,000+ open/close cycles
- High Volume: 10M+ units annual production requirement
- Stackability: Containers must stack securely for retail display
- Cost Efficiency: Competitive pricing for high-volume packaging
Solution
Our engineering team developed a comprehensive solution:
Material Selection
- FDA-compliant PP (Polypropylene) resin
- Living hinge-grade PP with enhanced flexibility
- Natural color for food-safe appearance
Hinge Design
- Optimized hinge geometry for maximum cycle life
- Proper material orientation during molding
- Controlled hinge thickness for consistent performance
- Cycle testing to validate 10,000+ cycle requirement
Production Excellence
- High-cavity production molds for efficiency
- Dedicated food-safe production area
- Contamination prevention protocols
- Automated inspection for critical dimensions
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Annual Volume | 5M units | 10M+ units |
| Hinge Cycles | 5,000 | 15,000+ |
| First-Pass Yield | 98% | 99.8% |
| FDA Compliance | Required | Verified |
| Customer Complaints | <100 PPM | 0 PPM |
Key Success Factors
- Material Expertise: Living hinge-grade PP selection and processing
- Design Optimization: Hinge geometry validated through testing
- Food-Safe Systems: Contamination prevention throughout production
- Volume Capability: High-cavity tooling enabling efficient production
Customer Testimonial
“CoreLMould’s living hinge containers have performed flawlessly. 10M+ units with zero quality issues and perfect FDA compliance. Their high-volume production capabilities and food-safe systems are impressive.”
- Packaging Director, Consumer Packaged Goods Company