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Story Behind the Award-Winning Blow Molded Product The Pickup Tuck cargo organizer

Award-Winning Blow Molded Product

By John Doster, president, and owner
SPI Blow Molding LLC

Originally published in the August 2019 issues of The Journal of Blow Molding, a Publication of SPE

Back in 2011, a small group of former automotive engineers and designers came together to bring one specific, innovative idea to life. Last year, 2018, that product – dubbed the Pickup Tuck – earned multiple honors from SPE. It took first place in the Auto/Transportation category of the SPE Blow Molding Division’s Industrial Awards and first place in the Industrial Division Awards, as well as the People’s Choice Award in the Industrial Category. This strong showing qualified it for entry in the ANTEC Plastics for Life Parts competition in Detroit in March, where it won the contest’s Quality of Life Award. This is the story of how that concept came to life, from its invention by automotive engineers, through its design by experts — including consultants from 99Studio Inc. and Garrett Engineering Services — to its manufacture by SPI Blow Molding

Award-Winning Blow Molded Product – An Innovative Idea

Former automotive engineer Jim Todd mocked up a “truck trunk” designed to prevent loose items from sliding to the front of his pickup truck’s bed. Todd made his initial prototypes out of wood and PE sheet and made copies of his invention for interested friends. With help from colleagues, Carl Powell and Russ Sheehan, Todd modified his concept, creating a portable truck-bed barrier made up of plastic panels that can be folded flat and stored in the truck cab when not in use. The panels stretch out across the back of the truck, from the passenger’s side to the driver’s side. To take it to market, in early 2012, the three formed a new company, TSP Enterprises. Powell serves as president and CEO, while Sheehan became VP of prototype and manufacturing engineering and Todd is VP of product concept engineering. Todd’s portable cargo organizer is different from cargo boxes that were already on the market because it is a temporary “trunk” that can be installed and taken down in a matter of minutes without any tools. With the tailgate forming one side, the panels create a box, covering and protecting contents from the elements. The panels corral loose items near the tailgate, preventing them from sliding around the truck bed and making it easy to reach them without having to climb into the bed. If the tailgate is locked, the contents also are secured against theft. Todd, Sheehan, and Powell helped make the prototypes, and TSP worked toward larger volume production of the panels. An award-winning blow molded product is the result.

Looking for the Right Partners

In May 2017, TSP approached SPI Blow Molding, a small custom blow molding company, to get a quote to see if manufacturing the product was feasible. TSP’s challenge was to determine the right manufacturing process and partner to help it build the tools, manufacture the parts and assemble the components cost-effectively. It looked at injection molding, rotational molding and thermoforming before concluding that extrusion blow molding (EBM) would provide the best shot at success. TSP determined that EBM was the right fit because the expected volume would quickly surpass the ability of rotomolding to produce parts cost-effectively. Injection molding would have resulted in parts that had one show side and a lot of structural ribs on the other. Meanwhile, thermoforming didn’t provide the required structural strength. EBM presents the perfect balance of part weight, cycle time, tooling costs and finished part appearance. SPI’s management team recognized the product’s utility and potential, and TSP chose SPI because of the manufacturer’s technical expertise in blow molding flat panels and willingness to partner and provide additional leadership and capital. As part of the companies’ deal, SPI holds an equity position in TSP.

Getting the Manufacturer Involved Early

A key to TSP’s success was getting SPI involved early in the process. The blow molder employs about 32 full-time employees and operates on a 24-hour, five-day-a-week production schedule. It runs a wide variety of resins on 13 EBM machines that can handle shot sizes ranging from 1 pound to 42 pounds. Its portfolio includes products for the agriculture, automotive aftermarket, food and beverage, industrial, marine, medical, military, pet supply, and transportation industries. SPI has also been recognized by SPE for other award-winning blow molded products, including the HDPE Buzz Ball Football game table.

In addition to its blow molded parts, the Pickup Tuck has one injection molded component — a part that’s made by SPI Industries LLC, South Bend, Ind., the custom injection molding division of SPI.

Benefits of Creating a Plastic Prototype for Production Molding

Benefits of Creating a Plastic Prototype for Production Molding
When you consider creating a new part that is to be made of plastic and the tooling cost is considerable, it is most desirable to test the functionality of the part prior to actually building the tool. Creating a plastic prototype can help determine if the part will function as designed. Modifications to a tool can not only be costly but degrade its overall performance and longevity.

The CAD Systems of today, such as Solid Works, which is what we use at SPI Blow Molding and SPI Industries provide a great deal of power to make changes to a part quickly as well as draw all related interacting parts to test the stack up interference fit required in a final assembly. Solid Modeling on the computer has replaced the need for some part prototyping of the past. None the less, there are several current approaches to making a prototype of the product that remain relevant today.

Plastic Mold Modeling:

Historically the only approach was to have a model made by a professional model builder.  The prototype may have been constructed of wood, plastic or metal depending on the size and function of the test needed to be performed on the prototype to prove its size and function.  Many parts today still require a fully functioning prototype model to get exact data from which a mold can be built.  It is a small price to pay for a good prototype part to avoid or at least reduce the iterations of design changes often required while designing and developing new parts and new products.

Rapid Prototyping:

Modern technology, such as Plastic Part Printing, has made prototyping not only less expensive but extremely quick to completion.  In today’s fast paced manufacturing arena the quicker a product can move from the sales planning stage to the manufacturing floor the better.  The life span of a consumer product has become incredibly short, thereby increasing, the pressure to develop new products even faster.  An example of how SPI Blow Molding recently used Rapid Prototype Printing to solve a problem for one of our customers, The Best Bins, was the development of a Portion Control Cylinder which was to be retrofitted into a current bulk food container dispensing unit.  Our engineering department drew the new portion control cylinder using Solid Works.  The drawing was then sent to the Rapid Prototype Entity, where it was produced.

The Plastic Printer, working similar to laying down ink, uses heated plastic resin instead of ink.  The printer then makes repeated passes just as it would if printing on a piece of paper, only it continues to make passes laying down a thin film of plastic resin with each pass.  Each pass prints a slightly different geometry, thus changing the shape of the plastic that is being printed. Each pass also moves up slightly preparing for the next pass.  This process is repeated hundreds and hundreds of times, until a completed part has been produced.  The part can be hollow or in nearly any shape, making it a perfect process to prototype parts for both Injection Molding and Blow Molding, which is what we do here at SPI.

Blow molded plastic bin dispenserThe Prototype Portion Control Cylinder was then tested for the amount of product it would allow to move though the dispensing unit on The Best Bins Bulk Food Container.  The amount was not what we wanted.  Four versions of the prototype part later we were all pleased with the outcome. At that point we were ready to build a new tool.

The amount of time and money saved by being able to rapid prototype this part was significant to our customer.  Without this testing capability we would have been forced to rebuild a mold cavity multiple times, which is both expensive and destructive to the integrity of the new tool.

It should be noted this approach is best used to determine size and fit, not strength and toughness.  Material characteristics will be very different in the prototype than in the final molded version.

Pull Ahead Cavities:

Another approach to prototyping is the concept of pulling forward a cavity in a multiple cavity tool.  If the project is for medium to small plastic parts, then it is very common to use a tool in production containing several cavities of the same part.  In this case it is sometimes wise to build one cavity and use that cavity to product prototype parts.  If changes are required, modifications can be made to that cavity only, allowing all subsequent cavities to be constructed to the newly proven geometry; resulting from the testing on the prototype (pull ahead) cavity.  This is also the prototyping choice where many parts are required for testing and the test challenges the strength and toughness characteristics.

Pull-Ahead-Cavity-plastic-liquid-dispenserSPI Industries used this technique in developing a new plastic collar for Monsanto’s 1 gallon Pump n’ Go “Round-Up” dispenser.  The new tool was to be 4 cavities.  SPI used Mold Flow Software to assist with the tool design.  It was then determined a Pull Ahead Cavity was the right way to go so extensive testing could be done before completion of the other three cavities. We did discover additional changes to be made and thus preserved the strength and durability of the final three cavities.

Reap benefits of creating a plastic prototype for production molding. SPI Blow Molding and SPI Industries injection molding specialize in custom solutions and mold design. SPI Blow Molding and SPI Industries injection molding specialize in custom solutions. Bring us your plastic parts and plastic product manufacturing challenges and let us get to work creating solutions.

SPI Expansion in the News

SPI Blow Molding Expansion in the News

Thanks to everyone at Tri-City Record for publishing SPI Blow Molding expansion in the news. Below is the recent newspaper article about SPI Blow Molding expansion published in the Tri County Record in Watervliet, Michigan. 

Please contact Karl Bayer, editor & publisher of  Tri-City Record P.O. Box 7  • 138 N. Main St., Watervliet, MI 49098 or call 269  463-6397.

SPI Blow Molding completes major expansion project in Hagar Township

SPI Expansion in the NewsSPI Blow Molding recently celebrated the completion of their 6,000 square foot warehouse addition with a formal ribbon cutting July 13, 2015.

John Doster, President of SPI and Izzy Dimaggio, Hagar Township Supervisor handled the honors.

The entire Hagar Township Board as well as some interested members of the community attended the ceremony, which was followed by a tour of the plant, an explanation of what SPI Blow Molding does, and in general, how they do it.

Thad Rieder of Cornerstone Alliance was also in attendance. Rieder was instrumental in assisting SPI with the tax abatement process, which was unanimously approved by the Hagar Township Board.

Doster commented on how pleased the company was with the support they have received from not only the Hagar Township Board, but the State of Michigan as a whole.

“The support we have been given by the State of Michigan is more than expected. It all started with Cornerstone Alliance putting us in touch with the various other agencies which could help us stabilize and grow.” Doster said. “Michigan Small Business Development Corporation (MSBDC) helped us get the ball rolling. Cornerstone Alliance pushed us along and the Hagar Township Board capped it off with tax abatement support.”

It takes a village and in this case, it looks like the village won. It is nice to see the various governmental sponsored entities come to the aid of private enterprise and make things happen. Though this is on a very small scale, it represents what a larger team can do. SPI indicated they have added 5 new jobs since the approval of this new project.

SPI Blow Molding is a Custom Blow Molder of hollow plastic parts. They are an extrusion blow molder specializing in low to medium volume work, requiring a fairly large array of materials.

Their customer list includes major manufacturers such as GE Healthcare, making arms for MRI Beds, down to the small single product entrepreneur such as Best Bins, making bulk food dispensers.

They process basic polypropylenes and ethylenes to more difficult clear polycarbonates. SPI has molding size capacity from a single pound head through 40 lb head machines.

SPI is capable of assisting customers with product design, tool design, tool building and the ultimate production of finished goods. They are located at 3930 Bessemer Rd., Coloma, Michigan, 49038. They can be contacted at 269-849-3200 or visit their web site at moldedparts.com

SPI’s mission is to provide the best custom molding experience for the injection and blow molded requirements of its valued customers. This experience involves flawless support culminating in successful global product delivery.

SPI’s core software, mechanical, and human technologies insure future profitability and growth to its employees, community and customers. SPI’s commitment is embodied in its value statement and quality policy.

SPI Blow Molding molds the HDPE Buzz Ball Football game table that was awarded 2nd place at the Annual Society of Plastics Engineers’ (SPE) Awards.

The award was granted in the Industrial Blow Molding Division of the 2nd annual blow molded parts competition. The ABC, SPE Blow Molding competition showcases the latest innovations and advancements in the blow molding industry. The competition was held in conjunction with the 30th Annual ABC and SPE Blow Molding Conference in Chicago, October 5-7, 2014.

SPI Blow Molding Breaks Ground Expands Fulfillment Services

SPI Blow Molding expansion - fulfillment services department  Coloma, MI, SPI Blow Molding LLC, a custom blow molding company is increasing building capacity to implement fulfillment services.

SPI Blow Molding is the sister company to SPI Injection Molding, a custom injection molder in South Bend, Indiana,

The expansion is taking place in two phases. The first is a smaller 2,400 square foot storage building meant to house fixtures and support equipment to the blow molding and fulfillment functions. Construction of this initial phase began in October of this year and should be completed by mid-December.

The second phase, which will be connected to the northwest corner of the current production plant, will be 6,000 square feet. Its primary uses will be secondary assembly, warehousing of work in process and finished goods as well as providing additional capacity for customer supplied components. All of these functions provide added capacity to perform complete fulfillment services for SPI’s valued customers. SPI hopes to begin construction on the larger structure during the spring of 2015.

When both phases have been completed, SPI Blow Molding will have enhanced its ability to mold, assemble, box and ship products to their customers. Products can be fully assembled and drop shipped to end users. Companies can then choose to have blow molded plastic parts shipped to another of their production facilities, a distribution center or directly to their customers. Multiple loading docks allow for ease in large shipments and receiving. Shipments will be transported throughout the United States and overseas.

SPI Blow Molding Fulfillment Services Capabilities:

  • Manufacture, assemble, inspect, package, and ship final products
  • Drop ship orders to our clients’ customers
  • Ability to warehouse products for our customers
  • Dock to stock shipping
  • Ability to use third party transport, mail and delivery systems

SPI Blow Molding provides fulfillment services for The Best Bins Company, headquartered in Minneapolis. SPI currently produces, assembles, warehouses and distributes their bulk food container product line. The bulk container is used for dispensing coffee beans, candies and a wide variety of bulk food items. Having all these capabilities and fulfillment services under the control of the SPI production plants has improved efficiency and saved Best Bin Company both time and money.

SPI Blow Molding provides custom molds and class-A molded parts in a variety of colors. SPI Blow Molding resin capabilities include: High Density Polyethylene (HDPE), Low Density Polyethylene (LDPE), Polypropylene, K-Resin, Styrolux, Ethyl Vinyl Acetate (EVA), Polyurethane, Nylon, PETG, and Polycarbonate. Nutraceutical and food products are blow molded from an FDA approved resin.

Along with manufacturing custom molds and molding parts, SPI Blow Molding is a complete manufacturing, fulfillment and distribution center. Newly installed equipment and warehousing space will allow SPI to comfortably offer manufacture, assemble, inspect, package and ship final products.

Expanding SPI Blow Molding’s current manufacturing plant footprint to house the new fulfillment services department will also open up several new jobs to the area.

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SPI’s mission is to provide the best custom molding experience for the injection and blow molded requirements of its valued customers. This experience involves flawless support culminating in successful global product delivery. SPI’s core software, mechanical, and human technologies insure future profitability and growth to its employees, community and customers. SPI’s commitment is embodied in its value statement and quality policy.

SPI Blow Molding molds the HDPE Buzz Ball Football game table that was awarded 2nd place at the Annual Society of Plastics Engineers’ (SPE) Awards. The award was granted in the Industrial Blow Molding Division of the 2nd annual blow molded parts competition. The ABC, SPE Blow Molding competition showcases the latest innovations and advancements in the blow molding industry. The competition was held in conjunction with the 30th Annual ABC and SPE Blow Molding Conference in Chicago, October 5-7, 2014.

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Media Contact for SPI Blow Molding
John Doster 269-488-2752
john.doster@moldedparts.com
3930 Bessemer Rd
Coloma, MI 49038
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