Skip to main content
Sister Publication Links
  • Sustainable Plastics
  • Rubber News
Subscribe
  • Login
  • Register
  • Subscribe
  • News
    • Processor News
    • Suppliers
    • More News
    • Digital Edition
    • End Markets
    • Special Reports
    • Newsletters
    • Resin pricing news
    • Videos
    • Injection Molding
    • Blow Molding
    • Film & Sheet
    • Pipe/Profile/Tubing
    • Rotomolding
    • Thermoforming
    • Recycling
    • Machinery
    • Materials
    • Molds/Tooling
    • Product news
    • Design
    • Mergers & Acquisitions
    • Sustainability
    • Public Policy
    • Material Insights Videos
    • Numbers that Matter
    • Automotive
    • Packaging
    • Medical
    • Consumer Products
    • Construction
    • CEO Issue
    • Diversity
    • Best Places to Work
      • 2022 winners
    • Processor of the Year
    • Rising Stars
    • Women Breaking the Mold
  • Opinion
    • The Plastics Blog
    • Kickstart
    • One Good Resin
    • BRICS and Plastics
    • All Things Data
    • Viewpoint
    • From Pillar to Post
    • Perspective
    • Mailbag
    • Fake Plastic Trees
  • Shop Floor
    • Blending
    • Compounding
    • Drying
    • Injection Molding
    • Purging
    • Robotics
    • Size Reduction
    • Structural Foam
    • Tooling
    • Training
  • Events
    • Plastics News Events
    • Industry Events
    • Injection Molding & Design Expo
    • Livestreams/Webinars
    • Editorial Livestreams
    • Ask the Expert
    • Plastics News Events Library
    • Processor of the Year submissions
    • Plastics News Executive Forum
    • Injection Molding & Design Expo
    • Plastics News Caps & Closures
    • Women Breaking the Mold Networking Forum
    • Plastics in Automotive
    • Injection Molding & Design Expo
    • Reuters Responsible Business Europe 2022
    • Reifenhäuser Technologies Livestreams
    • Polymer Points Live
    • Numbers that Matter Live
    • Plastics in Politics Live
    • Sustainable Plastics Live
    • Plastics Caps & Closures Library
    • Plastics in Healthcare Library
    • Women Breaking the Mold Networking Forum Library
  • Resin Prices
    • All Resins
    • Commodity TPs
    • High Temp TPs
    • ETPs
    • Thermosets
    • Recycled Plastics
    • Historic Commodity Thermoplastics
    • Historic High Temp Thermoplastics
    • Historic Engineering Thermoplastics
    • Historic Thermosets
    • Historic Recycled Plastics
  • Rankings & Data
    • Injection Molders
    • Blow Molders
    • Film Sheet
    • Thermoformers
    • Pipe Profile Tubing
    • Rotomolders
    • Mold/Toolmakers
    • LSR Processors
    • Recyclers
    • Compounders - List
    • Association - List
    • Plastic Lumber - List
    • All
  • Directory
  • Custom
    • Sponsored Content
    • Conair Sponsored Content
    • KraussMaffei Sponsored Content
    • ENGEL Sponsored Content
    • White Papers
    • Classifieds
    • Place an Ad
    • Sign up for Early Classified
MENU
Breadcrumb
  1. Home
  2. News
February 16, 2018 01:00 AM

Wine and molding

Roger Renstrom
  • Tweet
  • Share
  • Share
  • Email
  • More
    Print
    Sussex IM
    Sussex IM Account Manager Angela Klein, left, and Jessica Bell, owner and inventor of HaloVino, examine product components during one of the preliminary qualification runs of the newly-built 4+4 cavity family production injection mold.

    Jessica Bell has created a plastic wine glass that even a merlot-drinking wine snob can love.

    And she's working with Wisconsin-based custom injection molder Sussex IM Inc. for volume production of her HaloVino polypropylene cup.

    The two-piece cup is her solution to what she identifies as a "first-world problem" to create a wine cup for use in places unsuited for vessels of breakable glass.

    For any varietal connoisseur, "a plastic cup feels cheap" and the fermented juice does "not feel or taste like wine," she said in explaining the origins of her ah-ha moment. The glass's curved shape enhances the aroma of the wine, which helps offset complaints about the material for high-end wine drinkers.

    Bell worked as a Goldman Sachs investment banker for three years, for a winery in Spain for two years, as a sommelier in New York for a year and as a wine school operator in Milwaukee and Chicago for 10 years.

    After coming up with her idea for HaloVino, she connected with Sussex IM to bring the idea to production in the U.S. and make ​ it shine.

    It is important for an inventor or entrepreneur to "surround yourself with people who believe in you," Bell said in a Milwaukee television interview.

    "I was lucky enough to find a local manufacturer, Sussex IM, so we are actually making these in Wisconsin," she noted. "It's a fantastic operation they have, and they are definitely a great support system for taking an idea to market."

    So far, Bell estimates that she has invested about $250,000 in bringing the HaloVino cup to market.

    The two pieces snap together to form the curved glass. The cups are dishwasher-safe and reusable. Websites list an eight-pack of shatterproof HaloVino tumblers for $9.99-$11.99.

    HaloVino

    The HaloVino wine glass is designed to improve the aroma of wine, a shape that allows it to better compete for wine lovers' use in places where they cannot use glass.

    Reshoring from China

    Sussex IM initially inherited a concept-proving 1+1 family-style injection mold from a HaloVino-retained tooling source in China.

    The tool was transferred to Sussex IM in July 2016. The first order of 15,000 tumblers was shipped in the first week of August 2016 to the 2016 Wisconsin State Fair.

    At the same time, the firm's toolroom in Sussex, Wis., went to work on changes. Sussex IM employs five journeyman mold makers for engineering and preventive mold maintenance functions.

    The shop made several modifications to optimize the prototype mold to facilitate what became the first 100,000 units of production.

    That volume far exceeded the expected life of the mold.

    Early market success and customer feedback preceded the planning and engineering of both the geometry and the manufacturing process for the next phase of production.

    In making changes, special attention was paid to the aesthetic elements.

    Sussex IM ordered the new 4+4 mold from Hartford, Wis.-based Mantz Automation Inc. The build occurred in Hartford. Mantz has another site in Fond du Lac, Wis.

    The mold is projected to cost $150,000.

    Subtle design elements of a proprietary nature improved the portable, leakproof assembly.

    Sussex IM designers utilized Autodesk Moldflow fill/flow analysis to help balance-fill the family tool's multiple cavities. Resin quantities differ for the top and bottom components.

    Improvements included a multidrop manifold system to minimize runner scrap and control flow marks and bubbles in the wall section. As a result of the mold flow analysis, the gate location was optimized to blend it into features of the assembly and improve venting. The ejection system was improved. Core-cavity interlocks ensured consistent alignment protecting shut-offs and the parting line minimizing split lines on the molded part. The tool was built with the capability to expand into multicavity automatic in-mold labeling.

    The resin selected for the project is a low-odor, good-clarity PP that has approval of the U.S. Food and Drug Administration.

    For quick responses, Sussex IM uses digitally printed in-mold labels — pre-cut plastic films — to customize HaloVino tumblers with artwork and messaging for specific brands and venues.

    "This enables Jessica to offer her customers the flexibility of a product decorated specifically for their event or promotion or general sale, [and] it is a cost-effective technique to differentiate the HaloVino tumbler from other offerings in this market," said John Berg, Sussex IM director of marketing.

    "We've been very pleased with the advancements made in digital IML," he said. "We use this method in several applications and appreciate the flexibility, dramatically shortened lead times and the ability to order both large and small volumes."

    HaloVino customers include the Milwaukee Repertory Theater, the Milwaukee Brewers' Miller Park and the basketball and entertainment venue BMO Harris Bradley Center. A venue can stack unassembled pieces for storage.

    Recently, Sussex IM took delivery of three new presses from KraussMaffei — two 222-ton KM 200-750CX models and one 378-ton KM 350-3000CX.

    Now, the processor operates more than 60 injection molding machines with clamping forces ranging from 25-955 tons.

    Processes include in-mold decoration, insert, multishot, co-injection, over-molding, auto-unscrew and living hinge.

    Sussex IM provides numerous customers with downstream value-added operations such as assembly, decorating and performance validation. The contract manufacturing services include final packaging and third-party logistics.

    Sussex IM employs 416 full-time, 15 part-time and 120 temporary workers; occupies 222,000 square feet in two Sussex facilities in Waukesha County; and had 2017 sales of $68 million. The 2018 projection is $77 million.

    Sussex IM owners include Keith Everson, CEO; Phil Salzman, vice president of operations; and Dave Guagliardo, chief financial officer.

    The company plans an expansion in the next year to accommodate advanced manufacturing cells.

    Sussex IM and other companies will have active roles at the NPE2018 exhibit of the In-Mold Decorating Association in booth WL-6 on level 2 of the Orange County Convention Center's west hall in Orlando, Fla., May 7-11.

    RECOMMENDED FOR YOU
    Plastics adapt to a rapidly changing auto market
    Letter
    to the
    Editor

    Do you have an opinion about this story? Do you have some thoughts you'd like to share with our readers? Plastics News would love to hear from you. Email your letter to Editor at [email protected]

    Most Popular
    1
    One-third of ExxonMobil shareholders back study on virgin plastics risks
    2
    Changes at the top look promising for Plastics Industry Association
    3
    Ford to use 20% recycled, renewable plastics by 2025
    4
    Rehau selling Russian operations as Ukraine invasion continues
    5
    Stellantis replaces North American purchasing chief amid supplier relations woes
    SIGN UP FOR TO RECEIVE THESE EMAILS AND ENEWSLETTERS
    EMAIL ADDRESS

    Please enter a valid email address.

    Please enter your email address.

    Please verify captcha.

    Please select at least one newsletter to subscribe.

    Get our newsletters

    Staying current is easy with Plastics News delivered straight to your inbox, free of charge.

    Subscribe today

    Subscribe to Plastics News

    Subscribe now
    Connect with Us
    • LinkedIn
    • Facebook
    • Twitter
    • Instagram

    Plastics News covers the business of the global plastics industry. We report news, gather data and deliver timely information that provides our readers with a competitive advantage.

    Contact Us

    1155 Gratiot Avenue
    Detroit MI 48207-2997

    Customer Service:
    877-320-1723

    Resources
    • About
    • Staff
    • Editorial Calendar
    • Media Kit
    • Data Store
    • Digital Edition
    • Custom Content
    • People
    • Contact
    • Careers
    • Sitemap
    Related Crain Publications
    • Sustainable Plastics
    • Rubber News
    • Urethanes Technology
    • European Rubber Journal
    • Tire Business
    Legal
    • Terms and Conditions
    • Privacy Policy
    • Privacy Request
    Copyright © 1996-2022. Crain Communications, Inc. All Rights Reserved.
    • News
      • Processor News
        • Injection Molding
        • Blow Molding
        • Film & Sheet
        • Pipe/Profile/Tubing
        • Rotomolding
        • Thermoforming
        • Recycling
      • Suppliers
        • Machinery
        • Materials
        • Molds/Tooling
        • Product news
        • Design
      • More News
        • Mergers & Acquisitions
        • Sustainability
        • Public Policy
        • Material Insights Videos
        • Numbers that Matter
      • Digital Edition
      • End Markets
        • Automotive
        • Packaging
        • Medical
        • Consumer Products
        • Construction
      • Special Reports
        • CEO Issue
        • Diversity
        • Best Places to Work
          • 2022 winners
        • Processor of the Year
        • Rising Stars
        • Women Breaking the Mold
      • Newsletters
      • Resin pricing news
      • Videos
    • Opinion
      • The Plastics Blog
      • Kickstart
      • One Good Resin
      • BRICS and Plastics
      • All Things Data
      • Viewpoint
      • From Pillar to Post
      • Perspective
      • Mailbag
      • Fake Plastic Trees
    • Shop Floor
      • Blending
      • Compounding
      • Drying
      • Injection Molding
      • Purging
      • Robotics
      • Size Reduction
      • Structural Foam
      • Tooling
      • Training
    • Events
      • Plastics News Events
        • Plastics News Executive Forum
        • Injection Molding & Design Expo
        • Plastics News Caps & Closures
        • Women Breaking the Mold Networking Forum
        • Plastics in Automotive
      • Industry Events
        • Injection Molding & Design Expo
      • Injection Molding & Design Expo
      • Livestreams/Webinars
        • Reuters Responsible Business Europe 2022
        • Reifenhäuser Technologies Livestreams
      • Editorial Livestreams
        • Polymer Points Live
        • Numbers that Matter Live
        • Plastics in Politics Live
        • Sustainable Plastics Live
      • Ask the Expert
      • Plastics News Events Library
        • Plastics Caps & Closures Library
        • Plastics in Healthcare Library
        • Women Breaking the Mold Networking Forum Library
      • Processor of the Year submissions
    • Resin Prices
      • All Resins
      • Commodity TPs
        • Historic Commodity Thermoplastics
      • High Temp TPs
        • Historic High Temp Thermoplastics
      • ETPs
        • Historic Engineering Thermoplastics
      • Thermosets
        • Historic Thermosets
      • Recycled Plastics
        • Historic Recycled Plastics
    • Rankings & Data
      • Injection Molders
      • Blow Molders
      • Film Sheet
      • Thermoformers
      • Pipe Profile Tubing
      • Rotomolders
      • Mold/Toolmakers
      • LSR Processors
      • Recyclers
      • Compounders - List
      • Association - List
      • Plastic Lumber - List
      • All
    • Directory
    • Custom
      • Sponsored Content
      • Conair Sponsored Content
      • KraussMaffei Sponsored Content
      • ENGEL Sponsored Content
      • White Papers
      • Classifieds
        • Place an Ad
        • Sign up for Early Classified