You dream of it anyway, packaging that is just perfect. Every time. No crazy edges, no weird stains, the right thickness everywhere. Especially if you’re in the food industry, you know how incredibly important it is that your product reaches your customer safely and attractively. To that end, packaging is your silent salesman and your faithful protector. But how do you really make sure those thermoformed trays, bowls or blisters are consistently top quality, batch after batch? That’s where innovation comes in.
You may be thinking “quality control? We already do that, don’t we?” Yes, that’s probably true. Many companies still lean on manual controls. But you know yourself that that can be frustrating. Your employees do their best, but it’s still human work. Sometimes a product with a small defect does slip through. Or the inspection takes too long, which slows down your production. You may wonder whether all these new gadgets are not enormously expensive and complicated. And you may even be a little afraid of hassles with implementation, or that the technology doesn’t quite deliver what it promises after all. You just want a solution that works, that gives you that security you’re looking for.
At Multitray, we understand this very well. As a family business with a passion for packaging, we see the challenges you face. That’s precisely why we embrace innovation, especially when it comes to quality. Because we dream of it too: delivering the most reliable packaging you could wish for. And for that, advanced techniques have become indispensable.
Why traditional methods fall short
Thermoforming is a wonderful process, but it also has its quirks. Consider small variations in material, temperature or vacuum that can have subtle effects on the final product. A manual eye can miss a slight color deviation, overlook a wall that’s just a little too thin, or fail to notice a tiny air bubble. And with thousands of packages per hour, it is simply impractical to check everything by hand for every possible defect. This leads to frustration, potential waste and the constant fear that something will go wrong anyway.
Your partner for perfection
Fortunately, technology is not standing still. The biggest breakthrough in quality control for thermoformed packaging is in automated systems that are much faster, more consistent and objective than any manual inspection.
One of the most important innovations is automated optical inspection (AOI). Think of it as super-sharp eyes that use camera systems to scrutinize each package as soon as it comes out of the machine. These systems can check thousands of points in milliseconds. They look for visual defects such as color differences, contaminations, scratches, dents, or incomplete shapes. The beauty of this is that they do it the same way every time, without fatigue or subjectivity. This takes away that frustration of inconsistent checks and replaces it with reliable, repeatable results.
In addition, there are in-line measurement techniques. This goes beyond just looking. Consider laser or sensor systems that measure the exact dimensions of the package. Is the length correct? The width? And crucially, is the wall thickness anywhere within tolerance? Especially with thermoformed products, where the wall thickness can vary depending on the molding depth, this is critical to the strength and functionality of the packaging. By measuring this during or immediately after forming, we can detect deviations at lightning speed and even adjust the production process immediately. This reduces waste and ensures that each package meets strict specifications. This is the kind of control you need for your fresh produce or delicate confectionery products.
How this provides unprecedented consistency
By integrating these advanced techniques into the production process, we create a feedback loop. The inspection systems continuously generate data. This data tells us not only whether a package is right or wrong, but also whether the process is slowly starting to deviate. This allows us to take preventive action even before bigger problems arise. It’s like an extra pair of eyes, or rather, thousands of eyes with built-in measuring tapes and intelligent software, keeping watch 24/7. This means fewer rejects, a more efficient process and most importantly, the assurance that the packaging you receive meets the highest standards.
The benefits for your business
So what specifically does this mean for you, especially if you are in the food industry?
- Increased food safety: Defective packaging can compromise the integrity of your product. Automated inspection greatly minimizes this risk.
- Compliance with standards: You more easily comply with increasingly stringent regulations and certifications for food contact materials. No more fear of audits.
- Reduced waste and costs: Detecting defects early and optimizing the process reduces waste, which is good for your wallet as well as the environment (something we at MultiTray are very much committed to with our circularsource approach).
- Improved product quality and brand reputation: Consistent, defect-free packaging contributes to a positive brand perception among your customers. You deliver what you promise.
- Efficiency: Automated systems are much faster than manual inspection, keeping the production line running smoothly.
Your reliable partner in quality
At multitray, we see ourselves as more than just another packaging supplier. We are a partner. A family of problem solvers who believe in craftsmanship, innovation and a personal touch. We continually invest in the latest technologies, not because we have to, but because we want to provide you with the very best quality. We understand that every customer is unique and has specific requirements. That is why we like to think along with you about the best packaging solution and the corresponding quality assurance. Whether you are looking for a standard solution from our many moulds or require customization, quality is always our top priority.
We’re happy to take that worry about the quality of your packaging off your hands, so you can focus on what really matters: your product.
Ready for packaging of the highest quality?
Innovation in quality assurance is no longer a luxury, it is a necessity if you want to ensure consistency, safety and efficiency in thermoformed packaging production. It takes away your frustrations, minimizes your fears and makes your dreams of perfect packaging a reality.
Want to learn more about how our advanced inspection processes can help you? Are you curious about the possibilities for your specific product? Or would you like to discover how we can develop the perfect packaging together with our new product tool, with built-in quality assurance? Feel free to request a quote or contact us. We are happy to talk further with you.
frequently asked questions about quality control in thermoforming
Is automated inspection really necessary, or is manual inspection sufficient?
Manual inspection can provide a basis, but for the consistency, speed and objectivity required in modern production processes, especially in the food industry, automated inspection is far more effective in detecting even subtle defects.
Are these innovations only for very large companies?
No, definitely not. Although the technology is advanced, it is increasingly accessible. And the benefits in terms of reduced waste and increased efficiency are relevant precisely to any business, large or small. At MultiTray, we tailor quality controls to the specific needs of your project.
How can I be sure that the inspection system detects the correct defects?
Good automated systems are trained on the specific packaging and types of defects that are relevant. Our expertise and experience ensure that the systems are finely tuned to the requirements of your product.
Don’t these inspections slow down the production process?
Precisely not. Automated in-line inspections are designed to operate at full production speed. In fact, by detecting deviations faster and adjusting the process, they actually prevent costly downtime and delays further down the line.
Is sustainable material inspected as well as “normal” plastic?
Yes, modern inspection technologies are flexible and can be adapted to different materials, including recycled PET (rPET) and other sustainable options. Quality and sustainability go hand in hand.
