Plastic retainers in Industry – Common Mistakes and How to Avoid Them

Ideally, a deep-drawn plastic tray and container are robust, have a long lifespan, and fit well.

We show you how to avoid cracks and improper handling with your plastic tray to extend its lifespan.

What does Ergonomics Have to Do with Plastic Trays?

With deep drawn plastic trays, the key questions are: What purpose will they serve, and how heavy will they be when filled? Plastic trays are carried from machine to assembly station or lifted out of packaging, KLTs (small load carriers), and boxes.

Keep in mind that for ergonomic handling, weight and feel need to be considered. According to occupational health specialists, even lifting weights of 25 kg for women and 40 kg for men can pose health risks if done just once. For this reason, we ensure that your plastic tray is loaded with a maximum of 14 kg or 35 kg when handled by two people.

In addition to maximum weight, your employees can be assisted with lifting, carrying, and placing plastic trays through support systems. Handles or grip indentations must be sufficiently stable and positioned to account for the tray's center of gravity when filled.

An ergonomic design adapts to the anatomy of the hand. The grip should be able to be fully wrapped by the hand, providing a comfortable, secure grip without wobbling. Any feeling of insecurity during handling should be avoided, and the tray itself must be stable.

How critical areas are stabilized will be explained in the next section.

Avoiding Bends, Cracks, and Warping in Plastic Trays

Plastic trays that bend or break when lifted create frustration at work. But where do bends and cracks in plastic come from? Plastic damage usually occurs due to:

• The load weight not being considered in the plastic design.
• The plastic failing to withstand sharp or pointed loads.
• The plastic tray being used for too long.

Can Plastic Trays Be Designed as Reusable Products?

Absolutely. Whenever possible, we strive to design plastic trays as reusable products because longevity is both economically and ecologically beneficial.

Plastic Trays – Key Criteria for Longevity

• How long will the plastic tray be in use?
• What will it be used for, and what will it carry?
• What are the load-bearing values in kilograms?
• Is it exposed to additional mechanical stress from the surroundings or contents?

Your plastic trays are equipped with reinforcement structures. We can add ribs, braces, or transition contours, use thicker base materials, and optimize the forming ratio and material distribution. Our experts will select the right material and, most importantly, the right material thickness for you. We focus on meeting your needs in a material-efficient way. Learn more in our design rules for plastic deep-drawn parts.

Special Applications of Plastic Trays

Custom Milling of Plastic Trays

Custom milling on the bottom of the tray

The use of plastic trays in industry is as diverse as the industry itself. From containment trays to washing and cleaning trays, and even food-safe containers, the possibilities are endless. A small sample of construction options:

• Special openings and cutouts can be added to the bottom for specific requirements.
• Connection systems to surrounding objects can be added.
• Tight tolerances? These can be maintained at critical points in the deep-drawing tool.
• Sensitive glossy trays can be specially packaged with film and intermediate layers to prevent scratches during transport and storage.

If you want to further protect the contents of the tray or prepare it for transport, a suitable lid is essential.

The Plastic Lid Must Primarily Fit – Both the Plastic Tray and Your Application

The lid is designed to seal the plastic tray, which serves various purposes, particularly in industries like food or pharmaceuticals where hygiene standards are crucial. The lid protects the contents from:

• Dust
• Contamination
• Particles

Additionally, both the plastic tray and the lid must endure sterilization, temperature resistance, and chemical resistance. Many other industries share these requirements, especially when handling sensitive, high-tech parts or transporting chemicals.

Plastic lids serve more purposes than simply protecting the contents. They can also prevent leaks or spills and serve as a stacking and interlocking system for storage and interim storage. It’s important to ensure the contents of the tray do not protrude over the lid. The tray's load should be fully submerged or level with the edge of the tray. Various sealing techniques can be used to prevent the lid from opening.

Depending on requirements, a plastic closure can be: loose-fitting, easy to remove → lid with clip closure held in place on the plastic tray with a plug-in mechanism → lid with pressure closure fixed to the plastic tray with hinges so that it can be opened and closed → lid with hinge. If the lid is made of transparent plastic, it provides sufficient visibility so that you can ensure that the contents are intact.

Avoiding Common Mistakes with Plastic Trays – Key Takeaways

To extend the lifespan of your plastic trays and avoid damage, pay attention to proper handling, use stable carrying handles, and monitor the load weight. Additionally, custom adjustments such as reinforcement structures and special packaging can help increase stability and protect the contents. In summary, plastic trays are highly durable and can survive many production cycles when handled properly.

Requesting the Right Product – Quickly Getting to the Perfect Solution

Get your custom rectangular, round, or shape-specific plastic container now. Click on "Containers" in the formary configurator. formary will ask for all relevant information. Still have questions or something to discuss?

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