HLP Klearfold recently purchased the worldwide patents for the InSight visual packaging system from ASG (the AGI Shorewood Group), with whom they previously had an agreement to license InSight. The system combines printed plastic sleeves and injection molded plastic end caps to produce a distinctive visual package. The sleeves are essentially tubes with the shape of the end caps determining the cross-sectional profile of the package. The end caps attach to the sleeves using a unique locking feature. Undercuts molded into the end caps engage die-cut tabs on the sleeves to join the components together securely. Packages can be designed so that end caps either lock permanently to the sleeve or twist off easily.
Insight is most suitable for larger volume applications, because up-front tooling costs for injection molded components can be expensive; production runs of 250 thousand pieces or more are typical. Procter and Gamble, Kao Brands and Johnson & Johnson have all used this package for some of their product launches.
For smaller volume applications, HLP Klearfold's Klearfold Keeper offers distinctive, non-traditional shapes at less cost. Like InSight, Klearfold Keeper uses printed plastic sleeves, but the sleeves lock to cost-effective, standard or fold-over vacuum-formed trays, rather than injection molded components. The vac-trays are fabricated to conform to the shape of the product and to the desired cross-sectional profile.
"InSight and Klearfold Keeper are perfect, complementary packaging systems," says Steve Frazier, HLP Klearfold's president. "Both packages offer similar unique geometries and a very distinctive shelf presence, but have different production volume sweet spots. Klearfold Keeper is more cost effective for lesser volume applications while InSight is more cost effective for high volume."
Although "cat's eye" is the most commonly used profile, both InSight and Klearfold Keeper packages can be designed in a near endless variety, including oval, round, rectangle, square, and trapezoid. Both systems provide package security without the use of wafer seals or sonic, RF, or heat sealing.