Custom thermoformer and contract packaging firm Flexpak Corp. of Phoenix added in-line capability to form trays with a trim length measuring 50 inches, a significant increase from its past process.
“Our engineering and operations groups created a solution to form the longer length in our existing formers,” said Jim Boley, vice president of business development.
Boley said Flexpak's only new purchase was a Visual Packaging roller die-cutting unit purchased from Thermoforming Machinery and Equipment Inc. of Solon, Ohio. The cutting unit is used on an existing Sencorp 2500 machine.
Flexpak made its first delivery of 44-inch-long medical catheter trays in December. Previously, equipment restraints limited the length of Flexpak trays to 32 inches.
Boley said Flexpak delivers more than 1 million catheter trays annually.
Flexpak displayed samples at the Medical Design & Manufacturing West trade show, held Feb. 14-16 in Anaheim.
Flexpak employs 75 and operates eight thin-gauge thermoforming machines in its production of trays, clamshells and blisters for medical, electronics, food, retail and cosmetic packaging applications.
Flexpak is on track to convert to complete employee ownership by the end of 2020. Currently, employees own more than one-half of the company. The employee stock ownership plan was launched in 1988.
Boley predicted that Flexpak should see a 5-10 percent increase in sales during 2012 vs. its flat result during 2011.