Extrusion & Thermoforming

Our extrusion capability complements PFF's thermoforming operations. Thermoformed products provide a reliable and cost-effective solution to retail and transit packaging.

Extrusion

PFF is a vertically integrated business. We produce our own sheet plastic from a high quantity of food-grade post-consumer recycled (PCR) polymers. We also reprocess our own internal production generated waste.

Pellets are expertly blended to produce sheet material that meets direct food contact applications such as microwaveable, deep freeze, high clarity and silicone-free packaging. High-quality decoration can be provided by dry-offset printing or pre-printed sheet options.

Extrusion is suitable for a wide range of food quality packaging solutions as well as FFS applications.

Technical specification
Suitable for direct food contact applications
Material options: polypropylene and PET (the latter can have an optional PE laminate)
Sheet produced to a range of gauges from 200 to 1000 micron
Variety of colours and Pantone references
Standard, high-barrier and deep-freeze food applications
Internal anti-slip blends to mitigate sealing and label application issues

Environmentally friendly
ABA construction for our rPET, encapsulating recycled content with a virgin capping layer to ensure a 100% consistent sealing surface. Our rPET contains at least 50% of post-consumer recycled wastes and at least 30% of PFF’s own post-process waste.

Extrusion Measuring System

PFF has invested in extrusion measuring systems at Keighley and Washington which gives us the ability to produce a very accurate, uniform polypropylene sheet that is uniformly flat all the way across. SBI systems monitor the sheet constantly and give us the ability to adjust the machines to maximise the specification parameters and improve manufacturing efficiency.

We see this as an environmental investment as much as a business efficiency investment. It results in less waste and a more focused product environmentally with less plastic being used. And, it gives us the opportunity to be very accurate with customer specifications, rather than operating above and below target weight.

Thermoforming

PFF uses the sheet material that we produce on-site to manufacture thermoformed products.  They provide a functional and safe method of transporting and displaying goods within the food and non-food retail sectors. Crystal clear PET offers excellent clarity and our many unique shapes can maximise food proportion, perception and visibility. PFF also offers high-quality decoration through our dry offset printing or in-mould labelling services.

Technical specification
Suitable for direct food contact applications
Material options: polypropylene and PET (the latter can have an optional PE laminate)
Full range of sizes and shapes and colour capabilities
Bespoke and standard lines
Standard, high-barrier and deep-freeze food applications as well as laminated materials for MAP

Environmentally friendly
Thermoformed rPET contains at least 50% of post-consumer recycled wastes and at least 30% of PFF’s own post-process recycled waste.
Polypropylene is available with 30% of recycled content to help reduce the reliance on virgin polymers.

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