• Largest thermoforming company in Malaysia
  • ir@@scgmbhd.com

Business Process

Business Process

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MANUFACTURING PROCESS FLOW

One Stop Solution from resin to raw material and plastic packaging material

Our core business products can be classified into the following categories:

 

THERMO-VACUUM FORMED PLASTIC PACKAGING

 

We have more than 5,000 different moulds in current use to form thermo-vacuum formed plastic packaging products, We have the capabilities to thermo-vacuum form single-layer and multilayer extrusion sheets into plastic packaging, with thickness ranging from less than 0.11mm to 2mm, the extrusion sheets we use in our thermo-vacuum forming process are APET, PET-G, GAG, PVC, HIPS, PP and OPS sheets.

Our packaging is used to pack a variety of food products, including sandwiches, cakes, chocolates, biscuits, salads and moon cakes. Meanwhile, we are able to produce antistatic and black conductive trays to hold semi-finished electronic products, such as liquid crystal display and hard disk drive parts, as well as packaging to store end-products, such as computer software

Thermo-vacuum formed plastic packaging for food products should not contain any components that could migrate into the food, including harmful chemicals, contaminants and other relevant ingredients. They should also adequately protect the quality, freshness and safety of the food products, and ideally add to the appeal of the product by having attractive designs.

Similarly, thermo-vacuum formed plastic packaging for electronic products should adequately protect the products, for example from theft and/or damage, and at the same time provide total product visibility to showcase the products, if it is displayed in retail outlets.

Our thermo-vacuum formed plastic packaging is capable of both providing protection to our customers’ products as well as adding an aesthetic value to these products, which enhances their value and presentation.

 

EXTRUSION SHEETS

 

We produce extrusion sheets, namely, APET, PET-G, GAG, HIPS and PP sheets. These extrusion sheets are semi-raw materials used in the production of thermo-vacuum formed plastic packaging.

We began producing HIPS and PP sheets back in September 2004. Subsequently in March 2007, we started producing APET, PET-G and GAG sheets. Our HIPS, PP, APET, PET-G and GAG sheets are either used as semi-raw materials in our production of thermo-vacuum formed plastic packaging or sold to our customers.Back in FY 2006, our sales of extrusion sheets to external customers contributed only approximately 5.0% to our total revenue but has since increased significantly but will vary
according to demand. Currently, the sales of extrusion sheets contributed approximately 14.8% to total revenue.

An overview of our production process is shown below :

Once orders are received from our Sales Department, the Production Department would check our internal schedule and plan the production timeline as well as request for the required materials and/or moulds. Depending on the production process, materials required are plastic resins, colour master batches and additives, or extrusion sheets.


Plastic resins, colour masterbatches and additives are purchased from our suppliers. Meanwhile, extrusion sheets are either internally produced or sourced from our suppliers. On the other hand, moulds used in our thermo-vacuum forming process are designed and prepared internally by our Moulding Department, based on customers’ requirements.


Once we have all the required materials and/or moulds, we would conduct the extrusion process and/or thermo-vacuum forming process, depending on the customer requirements.

 

Our customers normally provide us with either a sample of the product that needs to be packaged, or a drawing of the packaging they require. If we receive a product sample, we would proceed with mould design. Moulds determine the shape and dimension of the thermo-vacuum formed plastic packaging produced. On the other hand, if we receive a rough sketch of the packaging required and the dimensions are inaccurate, we would redraw the dimensions for the mould.

A prototype mould is produced based on the mould design. This prototype mould is fixed onto our forming machine to form a sample packaging, which is sent for QC checks to ensure that the mould and the sample packaging formed are as per specifications. The sample packaging is also sent to customers for their approval. The prototype mould is modified, if necessary, until it meets specified requirements.


The prototype mould is then used as a master mould, to form a set of identical moulds for the thermo-vacuum forming process. Each thermo-vacuum formed plastic packaging has one (1) mould design. However, a set of identical moulds with the same design is usually made to maximise the number of moulds assembled on a base plate. This allows more thermo-vacuum formed plastic packaging to be produced at one time and reduce the wastage of extrusion sheets.


Once the moulds are formed, we conduct parts work. Parts work involves drilling small air passages in the moulds, thereby allowing vacuum to remove air from the area between the sheet and the mould shape as well as hold the sheet against the mould’s surface during the thermo-vacuum forming process. All the moulds are then assembled on a base plate, and finishing is conducted to polish and clean the moulds’ surface.


A final QC check is conducted before the moulds are sent to the production line or to the store. The moulds are visually checked to see if there are any differences in size. If there are differences, the moulds are modified or new moulds are fabricated. Once the mould passes the QC check, they are sent either to the production line or to produce thermo-vacuum formed plastic packaging for our customers or to the store to be kept until such production process is required.


We have the capabilities to produce four (4) different types of moulds, the details of which are as follows:

(i) Aluminium


Aluminium moulds are mainly used to form packaging with more precise dimensions, such as packaging for electronic products. Our aluminium moulds are designed using CAD/CAM software and formed using CNC milling machine.


The CAD software produces the mould design, while the CAM software controls the CNC milling machine to ensure that moulds are made as per requirements. Meanwhile, the CNC milling machine conducts turning and machining processes, to change the shape and surface finishing of the aluminium into the required mould design.

Our aluminium moulds are durable and can normally last for approximately ten (10) years, depending on the usage. We do not currently produce all of our aluminium moulds so we have been to purchasing additional new CNC milling machines to allow us to produce more aluminium moulds in a shorter time frame.


(ii) Epoxy


Epoxy moulds are produced when aluminium powder is mixed with two (2) types of resins to harden it, and then cast using a plastic tray. The plastic tray is a duplicate from a master mould. Although epoxy is softer than aluminium, it is more economical. Furthermore, our epoxy moulds are durable and can also last for approximately ten (10) years, depending on the usage. We presently produce our own epoxy moulds.

 

(iii) Plaster stone


Plaster stone is normally used to make prototype/master moulds. It is cast out by mixing plaster powder with water, and then left to harden. Moulds made of plaster stone are not as durable as aluminium or epoxy moulds, but they are more economical and can be easily modified should customers require changes to be made. We presently produce our own plaster stone moulds.


(iv) Wood


Wood moulds are shaped into the design/pattern as required. Similar to plaster stone, wood moulds are not as durable as aluminium or epoxy moulds, and are used to make prototype/master moulds only. We presently produce our own wood moulds.

Materials are fed through a top-mounted hopper into the barrel of the extruder. A barrel is a hollow cylindrical container positioned horizontally in an extruder. Materials fed into the barrel are as follows:

Besides the barrel, the main components within the extruder are the screw, screen pack, T-die and cooling rolls. The T-die, which provides the final product with its profile, is adjusted according to product specifications. The extrusion process commences once the T-die is set.


The materials enter through the feed throat (i.e. an opening near the rear of the barrel) and come in contact with the screw, which is located within the barrel. The rotating screw forces the materials forward into the barrel, which is heated to the desired melt temperature of the molten plastic. The plastic resins melt gradually as they are pushed through the barrel. At the front of the barrel, the molten plastic leaves the screw and travels through a screen pack to remove any contaminants in the melt. After passing through the screen pack, the molten plastic enters the T-die and plastic sheeting is formed. The extrusion sheets are then cooled by pulling them through a set of cooling rolls.


A QC check is conducted on the thickness of the extrusion sheets. The ideal thickness depends on customers’ orders and we set a 2% tolerance on thickness variations. If the thickness is not acceptable, the supervisors would be informed to rectify the problem. If it is acceptable, the sheets would be rolled-up. Another QC check would be conducted to check on the weight of each roll of extrusion sheets. The ideal weight depends on customers’ orders and we set a 0.1 kilogram tolerance on weight variations for each roll of extrusion sheets. If it is not acceptable, the supervisors would be informed to rectify the problem. On the other hand, if it is acceptable, each roll of extrusion sheets would be packed and properly labelled.


The extrusion sheet rolls are stored until they are required for the thermo-vacuum forming process, or delivered to customers. The extrusion sheet rolls must be stored in a spacious, dry area with room temperature of ±30ºC, to prevent damage from heat, humidity and contamination.

 

Over 35 years experience and knowledge of international manufacturing standards, we are dedicated to provide the best and economical solutions to our valued customers. Serving more than 30 countries, we strive to provide the most competitive pricing with highest quality.

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Contact us

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    PTD109444 Jalan Sengkang,
    Kulai Johor 81000 Malaysia.

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    (+60) 7 652 2288

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    ir@scgmbhd.com

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    Mon - Fri   : 08:00 – 17:30

    Saturday   : 08:00 - 13:30
    Sunday     : Holiday