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In the food packaging industry, every second matters. Containers, lids, capsules, and cups need to be produced in massive volumes, at high speed, with perfect dimensional consistency and zero defects.

The secret? Injection molds optimized for thin-walled applications, capable of delivering reliable performance even at the fastest production cycles.

In this article, we’ll break down what makes a plastic mold ideal for thin-walled food packaging, and how Fesp Mold supports companies that need high-efficiency, high-precision tooling.

Thin-walled molding: the challenges of food packaging production

Food packaging often involves wall thicknesses of less than 0.5 mm. This leads to very specific engineering challenges:

• Very short cycle times, often under 3 seconds
• High injection pressure
• Risk of part deformation or warping
• Faster wear on inserts and cavity components
• Strict requirements for materials suitable for food contact

Not to mention the growing demand for lightweighting, sustainability, and cost-efficiency.

What makes a mold effective for food packaging?

A high-performance mold for thin-walled food packaging must include:

✅ Geometry optimized for high-speed filling
Using 3D simulations (Moldflow), engineers can refine flow paths and gating systems to ensure uniform filling, even in very thin sections.

✅Use of Hot runners system

Allow a better melt flow, avoid waste of material and maximize the injection speed.

✅ High-strength steels and coatings
To handle wear from high-pressure cycles, especially in multi-cavity tools. Treated steel and modular inserts increase durability and reduce downtime.

✅ Precision ejection systems
Fast cycles require quick and reliable ejection. Air-assisted systems with mechanical ejectors help maintain part quality and prevent breakage.

✅ Thermal control and fast cooling channels
Efficient cooling ensures consistent part geometry and helps reduce cycle times without compromising quality.

The concrete benefits: fewer rejects, higher productivity

Choosing the right mold brings measurable performance improvements:

• Up to 90% scrap reduction
• Fewer unplanned stops for maintenance or cleaning
• Faster ROI thanks to continuous production
• Dimensional consistency across millions of parts
• Lower energy consumption, fewer defective cycles

Fesp Mold's experience in food packaging molds

At Fesp Mold, we’ve been designing and manufacturing multi-cavity plastic molds for thin-walled food packaging for over 25 years.

Our full-service process includes:

• Technical consultancy from the early design phase
• 3D modeling and Moldflow simulation
• Precision moldmaking with high-speed machining
• In-house testing, sampling, and dimensional reports
• Ongoing maintenance and support

We serve packaging manufacturers that run high-speed, high-volume production with demanding cycle time requirements and deliver molds that work perfectly from the first shot.

Need a reliable mold for your next packaging project?

Whether you produce coffee capsules, dairy containers, or takeaway lids, we can help you reduce defects, improve cycle times and boost output.

👉 Let’s talk. Book a free consultation with our technicians

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We are excited to announce our participation in the major international trade shows in the plastics industry for 2025. We are ready to bring our innovations around the world.

First Stop: ArabPlast 2025

Our journey begins with ArabPlast, the most important international trade fair in the Middle East, which will take place from January 7 to 9 2025, at the Dubai World Trade Centre. This event will bring together the most influential professionals in the plastics, rubber, and petrochemical industries, offering a unique opportunity to explore the latest trends and technologies in the sector.

We will be in Hall 02, Stand D02-05, ready to showcase our innovative molding solutions and our latest bio project.

🔗 ArabPlast 2025 | Dubai, UAE | Italia Pavilion exhibitors catalogue

On the Agenda: PlastImagen 2025

After ArabPlast, we will move to Mexico City for PlastImagen 2025, scheduled for March 11–14 2025, at the Citibanamex Center. Organized with the Italian collective by AMAPLAST and PROMAPLAST, this event is the key reference point for the Central American market, offering an extraordinary opportunity to strengthen relationships and establish new collaborations.

You will find us at Stand 432A within the Italian Pavilion.

🔗 Home | PLASTIMAGEN® MÉXICO 2025

We look forward to welcoming you to our booths and showing you how FESP solutions can make a difference in your production.

Stay tuned for further updates on trade shows and our projects!

Follow us on our social media for all the latest news.

ESG rating systems play a crucial role in evaluating companies based on their environmental, social, and governance (ESG) performance:

. Environmental criteria assess a company's role as a guardian of nature.

- Indicate the percentage of your company products that can be considered recyclable/reusable?

a)     Lower than 20%

b)    Between 21% and 50%

c)    More than 50%

With over 50% of our products being recyclable or reusable, our company is leading the way in sustainability in the manufacturing industry. Our dedication to producing eco-friendly products shows our commitment to innovation and responsible manufacturing practices, ensuring we contribute positively to a sustainable future.

. Social criteria evaluate how it handles interactions with employees, suppliers, customers, and the communities it operates in.

- Do you provide an ESG assessment of your suppliers?

Fesp answer:

Yes, environmental certifications

Yes, social certifications (health and safety)

Yes, geographical proximity

We provide a comprehensive ESG assessment of our suppliers, covering environmental and social certifications, as well as geographical proximity. This ensures our supply chain meets high standards of sustainability and responsibility, reflecting our commitment to ethical practices and sustainable operations.

. Governance focuses on a company's leadership, executive compensation, audit practices, internal controls, and shareholder rights.

- Have you revised your strategy to seize the opportunities of the new development model focused on sustainability?

FESP answers:

-  Yes, we have changed our Organizational model

-  Yes, we have appointed a figure dedicated to sustainability

-  Yes, we have invested in technological upgrades

-  Yes, we have introduced an ESG impact assessment process

We've revised our strategy to embrace opportunities in the new sustainable development model. This includes changing our organizational model, appointing a dedicated sustainability figure, investing in technological upgrades, and implementing an ESG impact assessment process. These initiatives underscore our commitment to sustainability and position us for success in the evolving landscape of responsible business practices.

Today, sustainability has become central to various aspects of business operations. Society's expectations of corporations are evolving. In addition to focusing on traditional products and profit margins, companies are now increasingly expected to prioritize environmental sustainability and social responsibility. Following the direction set by the FESP’s Vision and Mission, we implement a robust and effective governance framework, promote a collaborative and progressive corporate culture, and aim for sustainable growth through environmentally friendly production methods and flexible operations.

In the field of mold making, achieving precise and high-quality results is crucial. One critical aspect that significantly influences the performance and durability of molds is surface treatment techniques. These methods play an important role in modifying and enhancing the surface properties of molds, thereby improving the quality, durability, and functionality of the molded parts they produce.

Surface treatment techniques encompass a wide range of methods, each serving specific purposes and offering unique benefits.

Polishing

One of the most common surface treatments in mold making is polishing. Polishing involves smoothing the surface of the mold to achieve a mirror-like finish. This not only enhances the aesthetic appeal of the molded parts but also improves the release properties, allowing for easier removal of the parts from the mold.

Texturing

Another widely used surface treatment technique is texturing. Texturing involves adding patterns or textures to the mold surface, which can impart unique visual or tactile characteristics to the molded parts. Texturing is particularly useful for creating decorative or functional surface finishes, such as matte, gloss, or textured surfaces.

Coating

Coating is another surface treatment method commonly employed in mold making. Coatings can provide various benefits, such as increasing wear resistance, enhancing corrosion resistance, or improving mold release properties. Common coatings used in mold making include PVD (Physical Vapor Deposition) coatings, which can provide hardness and abrasion resistance, and DLC (Diamond-Like Carbon) coatings, which offer low friction and wear properties.

Plating

Plating is a surface treatment technique also used to deposit a thin layer of metal onto the mold surface. This can improve the surface hardness, corrosion resistance, depending on the type of plating used. Common plating methods include electroplating, where a metal is deposited onto the mold surface through electrolysis.

In addition to these techniques, surface treatment in mold making can also include processes such as nitriding, ion implantation, laser incision, and more. Each method offers unique advantages and can be tailored to suit specific mold and part requirements.

Overall, surface treatment techniques play a vital role in enhancing mold performance and optimizing the quality of molded parts. By carefully selecting and applying the appropriate surface treatment method, mold makers can achieve superior results, ensuring the success and satisfaction of their customers in various industries.

At FESP, we leverage a variety of surface treatment solutions to enhance the performance and durability of our molds. Whether you're seeking improved wear resistance, better release properties, or surface aesthetics, we incorporate the right surface treatments to meet your needs.

Discover how we utilize surface treatments in our molds to achieve exceptional results. Contact us to learn more!