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Paper Machinery Corporation, a leader in package forming and converting machinery, has just launched the first commercial application of the Barrier PlusTM container in collaboration with ProCal. Barrier Plus is the brand name for PMC’s development of a pre-printed plastic container formed on PMC Machinery. ProCal, a manufacturing company based in South Gate California, is utilizing this revolutionary technology to produce their PicturePotTM containers for the garden and nursery market.

Looking for an innovative solution to meet growing demands for its herb, vegetable and flower pots, ProCal has distinguished its range of products from anything else in the market with PMC’s Barrier PlusÔ container. This is a first-of-its-kind development of a preprinted, polypropylene container formed from a flat sheet by anyone. The result is an increased production of pots that offer a proven mix of barrier, affordability and printability.

“Until Barrier Plus, printing, die-cutting and convolute forming of preprinted polypropylene has not been achievable. Modifying the polypropylene material was necessary for what has traditionally been achievable on PMC machinery with polyethylene-coated paperboard,” said Jerry Meier, vice president of PMC. “This is truly a technological breakthrough with clear advantages over paperboard as well as thermoforming or injection molding of plastics.”

“The difference between the Barrier Plus technology and our old manufacturing process is comparable to the performance of a Model T versus a Ferrari,” said Gary Vollers, ProCal’s president. “Assembling the quality, pre-printed pots from a flat sheet has enabled us to reach the highest production rate with the best product in our 20-year history.” In April 2004, ProCal installed the PMC 1002P machine, which runs at 200 cpm for pot sizes ranging from six ounces to 32 ounces. The PMC 1300P, which forms pots at 110 cpm for sizes 32 ounces to 120 ounces will ship in early summer.

Since ProCal pots are used to grow and transport plants, as well as maintain their presentation for retail, one of the most significant aspects of the Barrier Plus container are the holes punched inline into the sidewall and the bottom. This design provides drainage for excess water and facilitates air circulation, which is critical in maintaining healthy robust plants. For other products, the polypropylene material provides or can be modified to achieve unbeatable protection against moisture and gas absorption.

“Customer response to the new containers has been unbelievably positive, and the feedback tells us that our pots are better than anything else on the market,” said Vollers. He continued, “Since replacing our equipment and upgrading technology to Barrier Plus, we’ve significantly increased production with the same number of employees.”

According to Meier, Barrier Plus offers customers several value-added features. The plastic sheet is considerably thinner than the sheet used for thermoforming. It has significant amounts of minerals added which also reduces the plastic cost. At a production speed of 200 containers per minute, the PMC forming machine produces containers more economically and utilizes less costly tooling than other forms of plastic technology.

In addition to the greater productivity and production economics, the Barrier Plus technology has given ProCal’s PicturePots a distinct advantage in marketing. Plants today are merchandised by large all-purpose retailers like Home Depot, Lowes and WalMart. These retailers can now build loyality through brand recognition. ProCal is using the high quality graphics produced by Barrier Plus technology to build this brand recognition.

Picture Pots feature quality graphic reproduction with easy to read, easy to find information. This strengthens the communication throughout the grower to retail cycle. Growers know which pots to use, merchants know whether to display in sun or shade and consumers know the description of the plants purchased. The little descriptive sticks, which are always lost or the printed plastic tags laboriously wrapped around a plant’s branch, are no longer needed.

“As we continue to market this innovative technology, our customers don’t need to spend more money for increased value and quality,” said Meier. “Barrier Plus allows us to aid their efficiency and profitability with a revolutionary and patentable solution to plastic’s printing challenges.”

About Paper Machinery Corporation

Paper Machinery Corporation is the world’s leading source of forming machines for paperboard cups, canisters, and custom packages. PMC serves the plastic converting and packaging industries with its revolutionary Barrier Plus technology. PMC manufactures dependable, high quality cup and container forming machines for converters and manufacturers and has more than 1,500 installations worldwide. PMC’s 120,000-square-foot corporate headquarters and manufacturing facility is located in Milwaukee, Wis. The facility houses a state-of-the-art engineering department, CNC machining centers, and full machine assembly and testing centers. For more information, visit www.papermc.com.