Many producers are making the move from a one-step molding process to a more-efficient and cost-effective two-step process. But what is two-step molding and why are they making the move? 

One versus two-step molding

Traditional one-step molding processes are generally geared towards applications that require lower annual outputs. Finished parts are usually made from PET and are created in a single cycle by a single machine with the injection, stretch and blow of a package taking place in the same machine.

With two-step molding, parts are typically produced with either virgin or recycled PET material, using two different specialized processes. In phase one of the two-step molding process, the first machine creates PET “preforms” via the process of melting resin, which is then injected into a mold cavity via a hot runner. In phase two, a second specialized machine heats up the preforms, then stretches and blows them into the final package shape.

Is two-step molding right for you? 

Switching to two-step molding offers significant potential savings and increased output, but is it right for your production needs?  Whether it makes sense to switch will depend on many factors, including your current application and your annual output volumes. Generally speaking, the best candidates for switching are packaging producers in the following industries:

• Food and beverage
• Household products (detergents, cleaning products)
• Pharmaceutical
• Personal care

The benefits of switching to two-step

Two-step molding can deliver incredible economic value and offers significant benefits over one-step molding. Here are some of the benefits customers can realize in making the switch:

• Reduced package cost (up to 20%)
• Reduced package weight (up to 20% resin savings)
• Improved productivity (up to 9% improved uptime)
• Improved output (faster cycle times for higher volumes with fewer systems)
• Reduced operating costs (fewer systems for reduced labour and energy consumption)
• Package design flexibility (lighter weights, greater variety of designs and sizes)

How to get started

The experts at Husky can help you make the switch to two-step molding. We start with a financial analysis to explore if this is the right move for you and will work with you from planning to production.

To learn more about switching to two-step molding, download our quick guide: How to reduce your package costs with a more efficient molding process.

Alternatively, you can get in touch with our Husky experts to learn more and get started.