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How Scrap Plastic Becomes Useful Post Consumer Resin

The plastic recycling industry hasn’t always been widely accepted. This is often because early recyclers paid little attention to quality control, contamination, and durability of their products. However, Pano Cap has found KW Plastics in Troy, Alabama to be a manufacturer of high-quality recycled resins. KW Plastics is the world’s largest plastics recycler and post-consumer resin (PCR) supplier for High-density polyethylene (HDPE) and polypropylene (PP). We are pleased to offer their KWR 621 FDA to our customers for environmentally friendly PCR closures.

In 2013 KW Plastics received a letter of no objection (LONO) from the U.S. Food and Drug Administration’s Center of Food Safety and Applied Nutrition for the recycling process to produce post-consumer PP. The resin, commercially referred to as KWR 621 FDA, is a food-grade PP resin and has been approved for levels up to 100%.

The source material used in KWR 621 FDA is strictly controlled. It is derived from post-consumer rigid packaging items that have been diverted from landfill and recycled—such as yogurt and cottage cheese containers.

After it is delivered to KW Plastics the recycled plastic is inspected. It is then ground, washed, and stored in flake form. Subsequently, it is extruded into pelletized form and transferred to 200,000 lb blending silos where it is assigned a lot number.

To ensure impurities don’t get into the PCR, after the post-consumer scrap is washed, it is extruded through vacuum-vented extruders that have been outfitted with state of the art Ettlinger Melt Filtration Systems that can filter to 200-microns. The resulting resin pellets are light gray in colour with some minor aesthetic surface imperfections such as specs or color swirls.

Through creative packaging design, the resulting plastic can be enhanced with darker pigments or the existing colour and variations can be a featured as a benefit to environmentally conscious consumers. As well, when light colors are required, smaller amounts of PCR can be blended with virgin PP.

KW Plastics reports that PCR is popular for personal care packaging such as: caps, closures, tubs, lids, razor handles, tubes, toothbrush handles, etc. Pano Cap has successfully manufactured containers and lids manufactured from 100% PCR material for Lush Fresh Handmade Cosmetics an international cosmetic manufacturer and retailer.

Contact Pano Cap to discuss using PCR in your next sustainable closure project. We can help you decide on the right mix of virgin materials to PCR, colour, and other specifications.

Committed to minimizing our environmental impact, Pano Cap is a zero waste to landfill company. Our closed loop system reuses all reground materials and recent plant improvements have reduced our carbon footprint. Read about Pano Cap’s commitment to the environment.

 

October 2018 Tradeshows

October was a busy month for Pano Cap, we took part in Pack Expo and NACD Chicago. It was a great success and it opened doors for discussion on our customers’ unique requirements and on Pano’s capabilities & newest innovations. We appreciate all the comments, queries, interest and the general support you expressed for Pano Cap. We would like to say thank you to everyone who took the time to stop by our booth.

 

Choosing a Cap or Closure

Choosing a Cap or Closure

There are several things to consider when choosing a plastic cap for your products.

Container Size & Construction

First, you need to know the precise neck size of your bottle, jar or container and what type of plastic it is made of—ask your packaging manufacturer.

Cap Size, Depth, and Feel

Then you need to select a compatible sized closure. Pano Cap offers standard 400 finish plastic caps from 28mm- 120mm, as well as, 28mm flip caps. See our full selection of sizes.

You will also need to choose a shallow or deep skirt for your cap. The height of your bottle neck may dictate the depth of your closure. With shorter necks you can only use shallow skirts. Closure depth impacts the look and feel of your package and affects how it is capped. Our sales staff can walk you through the right choice.

Another feature that shapes the look and feel of your package is the texture of your closure. Depending on your product and your end-users, you could choose fine ribs, coarse ribs (which make gripping and opening easier), or a smooth surface.

Tamper Evident Closures

Tamper Evident caps deter opening products before purchase, prevent removing or poisoning products, improve closure strength during shipping, protect the liner and provide clear evidence of tampering. Pano Cap pioneered the first Tamper Evident (TE) closure in 1983 and continues to provide the widest selection of innovative secure closures in North America. TE closures come with shallow or deep skirts.

TE closures are a regulatory requirement for supplements and other nutraceuticals, as well as, medications and other pharmaceuticals. They are often used for food or beverages such as ketchup, mayonnaise, coconut oil, salad dressing, nutrition powders, milk or juice.

Liners

Liners are the material that sits between a closure and your bottle or jar. Many dry, solid products don’t require a liner, while liquids, powders, and pastes do. Liners help with proper sealing of products and often improve the fit of a cap. Liners touch your products; therefore, it is critical that they are chemically compatible. Choosing the wrong liner could shorten shelf life or lead to leakage during shipping.

Pano Cap offers the following liners:

  • Foam (generally used for liquid products)
  • Venting (best for dry products that require ventilation)
  • 1-piece heat induction liners (foil, creates tamper evident packages)
  • 2-piece heat induction liners (foil, creates tamper evident packages and the secondary liner prevents leaking after the cap is re-applied)

Pano Cap heat induction liners are available in Full Weld Seal and Easy Peel. Our liners come in round cut and tabbed options. Tabs help to keep the liner in place during the capping process and give your customers something to grasp as they remove the liner.

Colour

Review our selection of commonly used cap colours or suggest your own. We offer low minimum order quantities (MOQs) on stock colours and custom colours.

Specialty Decoration Options

To enhance the attractiveness of your packaging, Pano Cap offers custom embossing (raised design or lettering), debossing (recessed design or lettering), and In Mold Labelling—a new process where labels are molded directly into the caps to avoid fading, scratching, tearing and moisture damage.

Custom Caps

As an innovative company with an engineering department, full tool room, flexible mold machines, and a modern manufacturing line we can create a custom solution for your unique products. Talk to us about special considerations from additives, static control, and freezing to PCR options and environmentally-friendly materials.

When to Order Closures

To ensure there are no delays with delivering your products to market and no costly missteps, involve your closure company when you begin designing your packaging. Pano Cap can provide neck finish drawings and samples to your new equipment suppliers and help to solve problems that arise. We can also recommend product filling partners, packaging manufacturers, and other trusted partners.

CONTACT US to order samples or for assistance choosing the right closure for your products.

Introducing the new 120 Smooth Wall

In the constantly changing packaging industry, success requires an appropriate mix of creating and following trends. Here at Pano Cap we create unique closures that can always be modified to meet our customers’ needs and wants.

In recent years we have noticed that more and more customers are requesting smooth wall caps. A majority of these customers are in the Nutraceutical industry. Our 120mm Deep Skirt Smooth Wall was a result of these request.

Here are some of its unique features :

  • Smooth side wall and polished flat top;
  • Outside gated;
  • 400 finish;
  • 5 TPI;
  • Can be made in any colour;
  • Numerous lining options available.

Based on the positive feedback of the 120 Smooth Wall, Pano Cap is gradually working on making a full line of Smooth Wall, wide mouth caps. A smooth version of our 89-400 and 110-400 shallow caps will be the first to be produced.

50 years of Pano Cap Canada

Pano Cap Canada reached it’s 50th anniversary on January 20th, 2017. But the real celebrations were on June 9th, when employees, alumni, guests, suppliers, customers, and friends, came together to under the sun and enjoyed the occasion to the fullest. The hors d’oveurs were splendid, as were the appetizers, main course, and deserts (creme brule, delicious!). The beverages were as refreshing and plentiful as the conversations.

Former, current, and maybe even future presidents of Pano spoke, as no stone of Pano Cap’s illustrious history remained unchecked. Guests from Germany, Brazil, and every part of Canada and the US, enjoyed the live music, the maple syrup gift, and a walking tour of the facilities. The general great mood that surrounded the event was a true representation of Pano Cap’s spirit. All those who attended and contributed, not only on the day of the feast, but throughout the entirety of the 50 years of operation, are testaments to the foundation on which Pano Cap Canada is built: caring and helpful people!

If the celebration was any indication of the next 50 years then we say: onward!