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Until now, a plastic container featuring superb quality printing, a true barrier design and a variety of sizes and shapes was a combination unheard of for a single package. But a combination of technological breakthroughs have been brought together by Paper Machinery Corporation in the introduction of the packaging industry's first ever pre-printed convolute container.

Barrier Plus, the brand name for this innovative solution, unites the graphic appeal of paperboard containers with the performance advantages of plastic to create an entirely new packaging category. Along with the Barrier Plus brand, PMC is introducing two new machines, the PMC 1002P and the PMC 1300P, to form the containers. Barrier Plus technology advances the industry into new territory.

“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.”

Previously, plastic container technology required post printing or application of a secondary printed substrate such as label, shrink band or paperboard. This added cost and limited quality of the graphics. The difference with Barrier Plus is that printing is done on polypropylene sidewall blanks, prior to forming, to produce richer and more saturated colors and sharper images. The new Barrier Plus machinery then replicates the sequence of operations that go into making two-piece paperboard cups. The sidewalls are totally sealed, the rims are tucked-and-rolled and the bottoms are 360o double-sealed.

As a material, however, plastic possesses properties that are vastly different than paper. To accommodate it, critical components and systems of Barrier Plus machinery were specifically engineered for plastic. These include forming tools made of special alloys and modifications to PMC's patented heating system that seals the material.

The first commercial application of Barrier Plus technology was developed in collaboration with ProCal, a manufacturing company based in South Gate, California. ProCal was searching for an innovative solution to differentiate their PicturePot containers within the garden and nursery market.

According to Gary Vollers, ProCal’s president, “The difference between the Barrier Plus technology and our old manufacturing process is comparable to the performance of a Model T versus a Ferrari. 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,” he said. In April 2004, ProCal installed the PMC 1002P machine, which runs at 225 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 began production in late summer.

ProCal is using the high quality graphics produced by Barrier Plus technology to build brand recognition among competitive products merchandised by large all-purpose retailers like Home Depot, Lowes and WalMart.

“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 added, “Since replacing our equipment and upgrading technology to Barrier Plus, we’ve significantly increased production with the same number of employees.”

In addition to superior quality printing, Barrier Plus offers customers several value-added features, according to Mike Hansen, Manager of Market Development for PMC. 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 225 containers per minute, the PMC forming machine produces containers more economically and utilizes less costly tooling than other forms of plastic technology.

“As we continue to market this innovative technology, our customers don’t need to spend more money for increased value and quality,” Meier said. “Barrier Plus allows us to aid their efficiency and profitability with a revolutionary and patentable packaging solution. This technology provides exciting new packaging options for a wide range of product categories including those demanding moisture and oxygen barriers.”

With the appeal of high-quality printing; the protection of a plastic container; the versatility of different sizes and shapes; the speed of manufacturing; the economics of production; and the environmental consciousness of recycling and reduced scrap, Barrier Plus truly "packages" a revolution in container technology.

For more information, please visit www.papermc.com or call Jerry Meier at 414-362-8247 or Mike Hansen at 414-362-8235.