Trelleborg’s applied technologies operation is launching a range of castable Syntac thermoforming plug-assist materials to manufacture thermoformed food, beverage, and pharmaceutical packaging. The Syntac range of materials is designed specifically to manufacture plugs and other associated tooling used in thermoforming manufacturing, where the plastic substrate is molded over the plug using pressure forming to create a thin-gauged thermoformed usable end product.
Syntac CIS (Core Industrial Solutions), Syntac HTS (High-Temperature Solutions), and Syntac STS (Strong Tough Solutions) offer high performance, high-quality solutions that are easier to machine and faster to hot-swap than alternative materials. By casting the plugs instead of machining, customers can reduce the amount of wasted material and save time by removing the need for CNC-machining or outsourcing for those customers without access to in-house CNC-machining.
Kerry Lyons, business development manager for Trelleborg’s applied technologies operation in Rochdale, England, states, “Our Syntac range of materials have been specifically developed to meet the changing needs of our customers. They are available off the shelf with shorter lead-times than previously offered, with manufacturing taking place in our UK facility. Downtime is a real issue for manufacturers, by helping customers to select the right material, they can increase efficiency and improve productivity.”
According to the company, Syntac plug assist materials are available as cast, sheet, or bar systems, requiring no specialized tools to machine or finish. Suitable for use up +220 OC, the new Syntac materials offer improved material distribution, enhanced clarity, and consistent, reliable repeatability. Customer-specific inserts can be pre-fitted by Trelleborg to provide a hot-swappable component option, supporting the plugs’ easy attachment to either the ceiling or bedplate of the manufacturing equipment.
Lyons continues, “As part of the development process, our new Syntac materials have been engineered to be lightweight, durable and tough, offering a cost-effective alternative solution to traditional materials. Trelleborg’s applied technologies operation in Rochdale is able to offer additional value-added services to our customers including cast to shape and CNC machining options to further support our customers.”
Trelleborg’s Syntec CIS and Syntac HTS materials are made from high-grade epoxy resin and hollow glass microspheres (HGMS), with Syntac STS made from a novel thermoset polymer matrix.
Thermoformed packaging such as drinking cups, food containers, and pharmaceutical packaging is formed using plug assisted pressure forming. Syntac plug assist materials are designed to require minimal finishing with an A-class surface finish, resulting in greater repeatability, optimized material distribution, and increased plug life.
Trelleborg is a world leader in engineered polymer solutions that seal, damp, and protect critical applications in demanding environments. Its innovative solutions accelerate performance for customers in a sustainable way. The Trelleborg Group has operations in about 50 countries. The Group comprises three business areas — Trelleborg Industrial Solutions, Trelleborg Sealing Solutions, Trelleborg Wheel Systems, and a reporting segment, Businesses Under Development.
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Naresh Khanna – 10 February 2025
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