Omar Khalid
Plastic containers are ubiquitous and come in various shapes and sizes, from jars and bottles to tubs. They are lightweight, durable, and cost-effective, but plastic pollution is a concern. Building your own plastic shipping container is possible with the right tools and techniques. You will need a miter saw, a jig saw, a cordless impact driver, an industrial glue gun, and various types of screws. You can also use a power miter saw and a 3D model to help with the build. Once you have the necessary tools and materials, molten plastic is injected into a mold and cooled to create the container.
| Characteristics | Values |
|---|---|
| Process | Plastic injection molding |
| Tools | Miter saw, Jig saw, Cordless impact driver, Glue gun, Wood screws |
| Materials | Polypropylene (PP), Polyethylene (PE) |
| Molding | Molten plastic is injected into a mold and cooled |
| Cooling | Containers are cooled to retain their shape |
| Finishing | Trimming, polishing, and adding final touches |
| Advantages | Lightweight, durable, cost-effective |
| Disadvantages | Potential environmental impact due to plastic pollution |
| Best Practices | Use food-grade plastics for food containers, recycle plastic |
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What You'll Learn
Choose the right plastic
When it comes to choosing the right plastic for a shipping container, there are several factors to consider. Firstly, the intended use of the container is crucial. Different types of plastics offer varying levels of durability, strength, flexibility, and resistance to elements like chemicals, moisture, and light. For instance, HDPE (High-Density Polyethylene) is a popular choice for containers in the pharmaceutical, cleaning, and automotive industries due to its durability and chemical resistance. LDPE, on the other hand, is more flexible and commonly used in squeezable containers and food storage.
Another important consideration is cost. Plastic containers are generally more cost-effective than alternatives like glass, metal, wood, paper, steel, or aluminum. They are inexpensive to produce and can help reduce shipping costs due to their lightweight nature. Additionally, plastic containers are highly durable and require less maintenance, further contributing to cost savings over time.
The environmental impact is also a factor to consider. Recycled plastics or new composite materials can offer sustainability benefits and reduce environmental impact. Additionally, some plastics, such as PET (Polyethylene terephthalate), are widely recyclable, helping to reduce the impact of plastic waste.
It is also worth noting that plastic containers provide excellent barrier properties, making them ideal for food and beverage storage and transportation. They are sealed and intact, preventing insect damage, rust, and corrosion. Additionally, they are stackable, customizable, and easy to clean, making them a versatile option for transporting a wide range of products, from baked goods to electronics.
When choosing the right plastic, it is essential to consider the specific requirements of your product and industry. The weight of the contents, the level of protection needed, and any regulatory requirements, such as FDA approval for food and beverage containers, should all be taken into account to ensure the plastic container is fit for its intended purpose.
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Use a mould
Using a mould is a popular and versatile method for creating plastic shipping containers. This process involves injecting molten plastic into a custom mould, which can be created by a mould manufacturer.
To begin, you will need to decide on the type of mould and resin material for your project. Injection moulding is a common and cost-effective choice, but other options include blow moulding, compression moulding, extrusion moulding, and rotational moulding. Consider the properties of the cured material, ease of use during manufacturing, price, and regulatory compliance when selecting your materials. For example, if your container will be used for consumables or cosmetics, you will need to use food-grade plastic.
Once you have selected your materials, it is important to work with a reliable manufacturer who can offer product design support, mould-making, and injection moulding services. Look for a company with expertise and a long history of reliability. Opting for a supplier that also manufactures the parts can offer benefits such as sole source accountability and quicker transition from concept to production.
When creating the mould, the manufacturer will need to consider the size, dimensionality, and complexity of the product. The mould should be designed to address these factors, ensuring that the molten plastic can fill the entirety of the mould, including any crevices or complex shapes.
After the mould is created, the heated liquid resin or molten plastic is injected into the mould at high speeds. It then cools and hardens into the desired shape before being ejected for finishing, trimming, polishing, and packaging.
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Use cooling equipment
While plastic shipping containers are useful for a variety of applications, they can be susceptible to extreme temperatures. This is especially true during the summer months, when containers can reach up to 120°F at sea and 135°F on land. Therefore, it is important to employ strategies to cool your shipping containers to protect your goods. Here are some detailed instructions on how to use cooling equipment to achieve this:
Use Reflective Paint
Apply reflective paint to the exterior of your shipping container. Light-coloured paint, such as white or light grey, can help deflect heat away from the container, similar to how light-coloured clothing keeps you cool. Avoid dark paint colours as they tend to absorb heat.
Install Ventilation
Ventilation is crucial in maintaining cool temperatures within the container. Consider adding shipping container vents at each end to facilitate cross-ventilation, which will keep the contents dry and prevent humidity-related issues like mould growth. There are various vent options available, including fixed, louvered, and rooftop turbine vents. Louvered vents offer more flexibility in controlling airflow but are more expensive than fixed vents, which are simple and effective. Rooftop turbine vents are popular and effective but come at a higher cost.
Utilise Thermal Blankets and Styrofoam
Thermal blankets and Styrofoam are cost-effective solutions to maintain the integrity of your goods during transport. They act as insulation, helping to regulate temperatures and ensure safe delivery, especially for perishable or temperature-sensitive items.
Install Air Conditioning
If your shipping container is used as an office or workshop and you have access to a power source, consider installing an HVAC system or a basic window air conditioner. The cooling capacity will depend on the size of your container, and you may need a more robust commercial through-wall HVAC system for harsher climates.
Add Exhaust Fans
Exhaust fans can also help with temperature regulation. These fans typically come in sizes ranging from 10 to 36 inches and often include features such as fan guards, gravity shutters, and variable speed control.
Use Dehumidifiers
If your shipping container has electricity, consider using a dehumidifier to control humidity levels. Dehumidifiers help pull moisture out of the air, reducing the risk of mould and other issues caused by excess moisture.
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Finish with tools
While building a plastic shipping container, you will need to finish with tools that ensure the container is ready for use. Finishing tools are used to trim, polish, and add any final touches to the container.
Firstly, a decent power miter saw is recommended for cutting and shaping the container to the desired size and shape. A good jig saw will also be useful for more intricate cuts and details. To ensure the container is smooth and free of any sharp edges, sanding tools such as sandpaper or a power sander may be needed.
For any additional features or attachments, an industrial-type glue gun with high-temperature glue sticks or polyamide glue sticks is essential. This will help attach handles, hinges, or other accessories to the container. If using screws for assembly or reinforcement, a cordless impact driver with a bit holder and the appropriate screws, such as Spax #8 - 2 1/2" Torx head gold wood screws, will be necessary.
Finally, to ensure the container is ready for shipping, you may need to add labels or markings. This can be done with a permanent marker or a labelling machine, depending on the complexity and durability required for the markings.
Overall, the finishing process is crucial to ensure the plastic shipping container is safe, functional, and aesthetically pleasing.
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Ensure it's food-safe
When making a plastic shipping container, it is important to ensure that it is food-safe, especially if it is intended for transporting perishables or consumables. Here are some ways to ensure that your plastic shipping container is food-safe:
Firstly, use food-grade plastic. This means that the container will not transfer non-food chemicals into the food. According to the U.S. Food and Drug Administration (FDA), non-food grade plastic containers may contaminate food. Plastic containers intended for food must adhere to specific regulations to guarantee their safety. Food-grade containers are usually extremely clean, watertight, odourless, and free from mould or contamination. They must also never have been used to carry toxic chemicals.
Secondly, be mindful of the type of plastic used. Different types of plastic have different resin identification codes, which indicate their chemical composition and safety for food use. Generally, plastics with the codes 1, 2, 4, and 5 are considered safer choices for food storage. On the other hand, it is recommended to avoid plastics with codes 3, 6, and 7, as these may contain vinyl or polyvinyl chloride (PVC), polystyrene, or Bisphenol A (BPA), which has been linked to health risks.
Thirdly, avoid exposing the plastic container to high temperatures. Heat can break down chemical bonds in plastic, increasing the rate of chemical migration into food. This means avoiding the use of plastic containers in microwaves, dishwashers, or environments with extreme temperatures. Instead, transfer food to containers specifically designed for storing or reheating, and always follow the manufacturer's instructions.
Lastly, be cautious when reusing single-use containers. Some containers, such as disposable water bottles, are intended for single use only and may not be safe for reuse, especially if washed in the dishwasher. Always check the labels and look for containers marked as "dishwasher-safe" or "microwave-safe" if you intend to use them for these purposes.
By following these guidelines, you can help ensure that your plastic shipping container is food-safe and suitable for transporting food products.
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Frequently asked questions
You will need a mould, cooling equipment, finishing tools, and the right type of plastic.
A miter saw, a good blade for 2x2 cutting, a jig saw, a cordless impact driver with bit holder, an industrial-type glue gun, and various types of screws.
PP (Polypropylene) and PE (Polyethylene) are considered safe for food storage.
Inject molten plastic into a mould. Once cooled, you have your container. After moulding, the containers are cooled to retain their shape. Then, trim, polish, and add any final touches.
Avoid high temperatures with certain plastics. Ensure food containers are food-grade. Recycle when you can, as plastic pollution is a real concern.
