Both types of these trays can be produced on standard Commodore equipment with a few key upgrades. There are no changes to your thermoformer or extruder that will affect your ability to produce regular closed-cell foam, so you can easily switch between both types of foam with minimal waste. Unlike other processes, our absorbent foam does not require additional lamination equipment and material, as we are able to control the skin layer on the sheet to effectively mimic the properties of a lamination layer.
There are many elements to successfully producing these products. On the extrusion side, optimizing the chemical recipe and process conditions is critical, as is our proprietary die design that allows us to make our single lamination sheet, with skin on two sides and open cell in the center. Our thermoformers and tooling are designed to optimize the characteristics of the open cell sheet, maximizing secondary expansion and utilizing engineered venting and vacuum paths for optimal tray forming. We are proud to be able to offer these technologies to our customers so they can stay one step ahead of the demands of their marketplace.
Here is a comparison of the two types of absorbent trays, demonstrating the advantages and disadvantages of both approaches:
Trays with Foam Pad (A-Tray)
Advantages
- Maximum absorbency, as pad is all open cell.
- Maximum tray strength, as tray is all closed cell foam.
- Lower weight than paper padded trays.
- No leaking of purge through tray edge like absorbent trays
- Additional cost of making two separate parts, tray and pad.
- Additional labor required for padding operation.
Advantages
- Consumer demand is increasing. 60% of foam trays in European market are absorbent.
- No separate pad reduces production cost.
- More absorbent surface area for more potential absorbency.
- High open cell count makes for brittle trays.
- Higher weight required to compensate for brittleness.
- Purge is prone to leaking out from tray edge.
Typical Absorbency – 4D Tray
Padded Trays
- Paper pads…15-50 grams/tray
- Foam pads…30-65 grams/tray
- Polyacrylate pads…120-180 grams/tray
- 80-110 grams/tray
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