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Gillette pushes new thermoforming technology

A patented approach combines flexo printing and thermoforming in register to produce a tactile quality that really makes this thermoformed PET blister stand out.

Pw 61026 Gillette 2

From Procter & Gamble’s Boston-based Gillette division comes the well known and well established Venus line of women’s razors—Venus Quench, Venus Embrace, Venus Breeze, Venus & Olay, and others. Now comes Venus snap with Embrace™, a compact and portable version of the longer-handled shaving devices aimed specifically at women on the go.

The packaging is a common enough format: a trapped blister that is thermoformed of PET. But it’s no ordinary thermoforming that we’re talking about here. This package is one of the first commercial applications of a patent-protected technology from Canada’s think4D (www.think-4d.com). It combines printing and thermoforming in a way that produces a package having an unusually tactile quality. In fact, it’s as if the little shaving device itself is perched on top of the plastic thermoform.

According to Gillette’s Mike Marcinkowski, Principal Engineer R&D, Global Pack Dev, this package is an extension of some of the work Gillette has done in the past with Gillette Fusion ProGlide packages, where thermoforming is preceded by distortion printing. “But this goes much farther in terms of process and registration,” he points out. “The think4D technology takes us to a four-dimensional quality by making the package so tactile.”

Early applications of think4D’s technology tended to involve shallower thermoforms. In one case, four package-making steps were involved. First was flexo printing of PET sheet. In a second operation, the sheet was thermoformed to a shallow draw and individual thermoforms were die cut from the sheet. Next, a pressure-sensitive release liner was applied to the thermoform. Finally, the thermoform was pulled manually from its release liner and applied like a label to a conventional folding carton.

When applications like these reached Gillette’s radar screen, it caught their attention. But they wanted more.

Deeper draw
“It was Gillette that challenged us to go beyond a tipped-on label kind of approach and get to a deep-drawn package,” says Mike Fehr, President of think4D. Fehr explains that think4D is a division of Friesens Corporation, a Canadian book manufacturer. They’ve been around for more than 100 years, so printing is in their DNA. It was about five years ago that Friesens came across the intellectual property for the print/thermoform technology now being commercialized by Gillette. “It was mostly a concept,” says Fehr. “There wasn’t even any equipment in place at the time. But we really liked the idea, so we acquired the intellectual property with an eye toward increasing our print presence in spaces other than book manufacturing. An obvious place to focus on was packaging.

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