Making A Yeti Cooler: How Much Plastic Is Needed?

Yeti coolers are renowned for their durability and ability to withstand harsh conditions. The manufacturing process involves using a thermoplastic material called polyethylene, which is softened and rotated inside a mold to form the outer shell. This plastic shell is then injected with polyurethane foam, creating a rigid insulation panel that enhances the cooler's strength and insulating properties. The amount of plastic required for a Yeti cooler depends on the size and thickness of the shell, with the exterior being significantly thicker than traditional coolers. The process, known as roto-molding, contributes to the overall quality and performance of the cooler, resulting in a premium product with a high price tag.

Polyethylene plastic shell formed by rotational moulding

Yeti coolers are made from polyethylene plastic shells formed by rotational moulding. This process involves heating the plastic to a high temperature, causing it to soften, and then placing it inside a mould. The mould is rotated, causing the softened plastic to disperse and stick to the sides of the mould, taking on its shape. As the plastic cools, it solidifies and hardens, creating a strong and durable shell.

Polyethylene is a thermoplastic material, which means it can be easily moulded above a specific temperature and then becomes solid when cooled. This quality makes it ideal for use in rotational moulding, where the plastic needs to conform to the shape of the mould. Polyethylene is the most common plastic in the world and is used in a variety of products, from plastic bags to bulletproof vests.

The rotational moulding process for Yeti coolers ensures that the shell is formed in one piece, eliminating weak points and seams that could compromise its integrity. This results in a sturdy and durable cooler that can withstand heavy use and rough handling. The process also allows for flexible design geometry, although it is a manual, operator-dependent process that is relatively slow and low volume.

To prepare the polyethylene for rotational moulding, the plastic is ground into a powder. This powder is then placed inside a mould, which is heated and rotated biaxially in an oven. The slow rotation ensures that the powder evenly coats the interior surface of the mould before melting and fusing together into a seamless part. This results in a consistent wall thickness, which is a unique benefit of the rotational moulding process.

Overall, the polyethylene plastic shell formed by rotational moulding is a critical component of Yeti coolers, providing exceptional durability and strength. The process ensures that the cooler can withstand harsh outdoor conditions and heavy use, making it a trusted choice for adventurers and outdoor enthusiasts.

Polyurethane foam injected into the interior

The Yeti cooler is made from an outer shell of polyethylene plastic, which is roto-moulded. This plastic is much thicker than that of a traditional cooler, contributing to its strength. Polyethylene is the most common plastic in the world and is used to make everything from plastic bags to bulletproof vests. It is a thermoplastic, which means it becomes easily mouldable above a specific temperature and then becomes solid when cooled. The roto-moulding process involves heating the plastic to a high temperature and using low pressure to create a single piece of hollow plastic. This process eliminates weak points and seams that could compromise the integrity of the cooler, making it durable and less prone to cracking.

After the exterior shell is formed, the interior is injected with polyurethane foam, which sets hard. This foam adds to the strength of the cooler and gives it excellent insulating properties. The foam allows the cooler to keep ice for longer through a process called thermal conduction. The amount of foam injected can vary, but it is typically around two to three inches thick. This thickness ensures that the cooler has a high R-value, which measures the effectiveness of the insulation.

The combination of the polyethylene shell and the polyurethane foam insulation makes the Yeti cooler incredibly durable. It can withstand being driven over, thrown from moving vehicles, and even attacked by bears without breaking. This durability is one of the main reasons why Yeti coolers are so expensive and have become a status symbol in the United States. The manufacturing process, high-quality materials, and effective marketing all contribute to the premium pricing of Yeti coolers.

The roto-moulding process

Roto-moulding is particularly useful for creating hollow parts and double-wall containers, like coolers, as it allows for seamless parts with uniform wall thickness. The process results in a stress-free, lightweight, and durable design. It also eliminates weak points and seams, which could compromise the integrity of the product. This is why Yeti coolers are so strong and can withstand heavy use without cracking.

The cost of manufacturing

Firstly, let's consider the materials used in Yeti coolers. The coolers are made from polyethylene plastic, which is a common and widely available thermoplastic material. This plastic is used for the outer shell, which is formed through a process called roto-molding or rotational molding. This process involves heating the plastic and using a mold to create a hollow shell. The shell is then filled with polyurethane foam, which acts as insulation. The foam solidifies and hardens, increasing the strength and insulation performance of the cooler. Additionally, the coolers have various extra components, such as drain plugs, handles, hinges, feet, gaskets, and latches. These additional parts contribute to the overall material cost.

The labour cost of manufacturing Yeti coolers includes the wages paid to the workers involved in the production process. This includes the workers operating the roto-molding machines, assembling the coolers, and attaching the extra components. The labour cost may also include the salaries of the design and operations staff who are involved in designing new products, working with manufacturers, and providing customer support.

Marketing is another significant factor in the cost of manufacturing. Yeti has invested in highly effective marketing campaigns that promote an all-American, rugged, outdoor lifestyle. They have also hired prominent marketing professionals, such as the former head of marketing for Calvin Klein, to drive their marketing efforts. These marketing initiatives contribute to the brand's reputation and recognition, allowing them to maintain a premium pricing strategy.

Finally, distribution and sales play a role in the overall cost structure. Yeti closely controls its sales and distribution network, opting to sell their products through retail stores and speciality shops rather than discount stores. They have sales representatives in multiple countries driving sales into these retail channels. This extensive distribution network incurs costs, including transportation, storage, and potential margins or commissions paid to the retailers.

While the exact manufacturing cost is unknown, it is estimated to be a fraction of the sales price. Some sources suggest that the manufacturing cost could be around 10-20% of the price paid by consumers. This estimation, however, does not include the various other costs associated with running the business, such as marketing, distribution, and administrative expenses. Therefore, the total cost of manufacturing and bringing the product to market is likely much higher than the direct production cost.

The brand and its marketing

Yeti coolers are made from polyethylene plastic shells formed by rotational moulding. The polyethylene shell is an empty shell that is pressure-injected with up to three inches of commercial-grade polyurethane foam, which is an insulating material. The rotomoulding process involves moulding the cooler's shell in one piece, eliminating weak points and seams that could compromise its integrity. This process also allows the cooler to preserve ice for hours with vacuum insulation. Rotomoulded coolers are not prone to cracking and can withstand rough handling and heavy use.

Yeti coolers are designed and marketed as high-quality outdoor products that are durable and long-lasting. The brand has built a strong reputation for manufacturing products that are trusted by adventurers, anglers, and outdoor enthusiasts worldwide. This brand loyalty and trust contribute to the premium pricing of Yeti coolers. The company's effective use of the all-American, rugged, outdoor lifestyle in its marketing campaigns keeps customers coming back for more.

Yeti coolers are also known for their expensive price tags, which has led to some consumers opting for DIY alternatives or cheaper retail options. However, despite the availability of cheaper alternatives, the Yeti brand has been able to maintain its market position due to its strong brand recognition and the perception of quality associated with the brand.

The company has invested in effective marketing strategies, including hiring the former head of marketing for Calvin Klein as its Chief Marketing Officer. Yeti closely controls its sales and distribution to maintain the high price of its products and avoid discounting. They also have a network of sales reps in various countries driving sales in retail stores. In addition to their coolers, Yeti has expanded its product line to include items such as stainless steel vacuum-insulated tumbler cups and bottles, further diversifying their offerings and attracting a wider range of consumers.

Overall, the Yeti brand has successfully combined product design, marketing, and distribution strategies to create a strong and recognisable brand that resonates with its target audience of outdoor enthusiasts.

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