Welcome to eMold –
          
For all your Plastic Collapsible Tube Requirements!

Plastic Collapsible tubes provide a cost effective, attractive and durable plastic packaging solution for a wide range of consumer products. In addition they are increasingly being used to package products for the pharmaceutical, food and DIY market sectors.


Plastic Tubes are used to package the following products:


Cosmetic Creams , Shampoo , Shower Gel , Sunscreens , Inks , Paints , Eatable
Sauces , Motor Greases , Glues , Tile Grout

          “eMold offers plastic tubes to satisfied customers for over 15 years.”

We offer plastic collapsible tubes with a wide decorative appeal. Tubes can be decorated to match customer requirements within certain criteria. Designs can be reproduced in up to six colours using dry-offset litho printing or foiled using the hot-stamping process. In addition, tubes can also be printed using the silkscreen process for up to two colours or labeled through a third party.
eMold’s customers are well known contract companies that manufacture and supply oral, medical, pharmaceutical and personal care products throughout SA and Internationally.

Mission Statement
“We are committed to create a Quality product that our customers can be proud of.”


Product features

Protection
Plastic tubes offer effective protection for the majority of products which in turn safeguards the shelf life of the product.
UV inhibitors can be added to single layer tubes for increased protection for products susceptible to light degradation.
Sunscreens will turn a LDPE grade tube yellow in colour, in these instances, HDPE can be used to manufacture the tubes and therefore protect the tube from the product.
Durability
Plastic tubes do not require a protective outer carton, the material has "memory" which means it retains its shape well and can withstand the rigours of transportation and handling.
User Friendly
Plastic tubes stand upright on the tube cap and allow the product to be easily and hygienically dispensed. The durable nature of plastic tubes means they are suitable for use in many different environments from the bathroom to the beach to the workshop.
Point of Sale Appeal
The wide range of colours, finishes and decorative effects are on offer. This adds up to an attractive packaging solution which has a strong impact on the shelf and allows plenty of opportunity for product differentiation
Tube Caps and Closures
A wide range of caps are available including smooth sided, ribbed, rounded profile, disc top and flip top screw-on available in colours that can be matched to the artwork design, if preferred to white or clear.

Tube Decoration
Hot Stamping
Foil adds a final touch to the design of a tube and improves the appearance for premium products.
eMold offers a range of standard foils however it is possible to colour match foils to meet customer requirements but these would be subject to development lead times and minimum order quantities.
Tube Labelling
Labels can be used when complexity of design exceeds the boundaries of offset and silk screen printing. Labelled tubes are also useful when producing small runs for test marketing or foreign language variants.
Lacquer / Varnish
The finish of the tube can be enhanced with a final coating of gloss or matt lacquer. This process provides additional protection for the offset inks and tube.
Offset Printing
The most intricate designs can be produced in up to six colours using offset printing. Tubes are printed in-line using the rotary dry-offset process, designs range from line and text to more complex illustrations and vignettes.
Tube Colour
Tube colour can be matched to meet specific customer requirements, a wide range of colours, tints and pearlescent finishes can be achieved. However if the colour of the product is itself a feature then the tube can be produced in a clear polyethylene.



Tube Specification
Tube Dimensions and Tolerances
Tubes are in the following dimensions:

22mm

25mm

30mm

35mm

40mm

50mm

Tube Diameter Tolerance is +/- 0.3mm.
Wall Thickness: 0.50mm -0.45mm +/- 0.05mm (0.018 +/- 0.002)
Tube Fill Declaration Table
eMold can supply tubes from 65mm length to 185mm (depending on tube diameter). Tolerance is +/- 1mm for sleeve at a length of up to 100mm. Then +/-2mm extra for the sleeve length over 100mm.

	Tube Diameter (mm)
Tube Fill (ml)	22	25	30	35	40	50
13.5	74mm
15	74mm
25	103mm	82mm
30		94mm	80mm
40		118mm	105mm
75			105mm	85mm	85mm
100			140mm	120mm	100mm
125				150mm	125mm
150					150mm	115mm
200					165mm	127mm
250						150mm
						185mm
Circumference of tubes	69mm	78.5mm	94mm	110mm	125.5mm	157mm

N.B. The above tube fill lengths should be appropriate for the majority of products. However it is the responsibility of the customer to determine the suitability of the pack size and compatibility with the filling process.

Orifice Size and Details
Orifice sizes range from 1.5, 2.5, 3.5, 4.5, 5.5, 6.5, 7.5 depending on the size of the tube-head. Orifice size tolerance is +/- 0.15mm.

Materials Used
Tubes are manufactured using LDPE for clear tubes or a 20/80% blend of HDPE/LDPE is used for white and other colours. 100% HDPE is used for certain products like Sunscreens.
Decoration Tolerances
Offset print tolerance is 5mm, relative to the tube shoulder.
Hot Stamping (foil) tolerance is +/-1mm to design.

Production Processes

Extrusion
This is the first stage of production, the polymer is melted and combined with a masterbatch pigment (if the tube is coloured). The melted polymer is extruded into one long tube which is cut in to "sleeves" of the appropriate length. In this case the tube is natural or clear.




Heading
This is the next and final stage of the manufacturing process of the physical tube, before the decoration phase. The heads are injection moulded to the "sleeves" using a Vertical Injection Moulding machine like this one.








Litho Printing
(Dry offset) Decorating the tube is then done using a six colour Litho Printer. Here the tube gets the final look according to the Customer's Artwork spec before it may have to go to the Hot-Stamping process.






Closures
We have moulds to make caps for every size of tubes that we offer and if there is a special request, we can get a mould made. We also carry a 40mm and 50mm screw-type flip-top mould besides the 22, 30, 35, 40, 50mm screw-type caps.

Quality Control – Packing - Security
After the decorating process, each tube goes through a Quality Control person. The tube then gets a tamper proof membrane between the head and cap/lid and thereafter it gets packed in lined boxes by our trained packers.



About eMold

History
eMold was established in 1995 by two strong willed individuals in Germiston in a suburb called Delville. After 3 years, the operation was moved to Johannesburg where a building was leased in Booysens Reserve, and later moved to premises that we’re purchased in the same area.

Quality Product and Fast Turnaround
Apart from good knowledge of tooling and manufacturing, this business was formed with very little capital. The business was a long time dream, and even though circumstances were very much against the survival of eMold, it carried on to become a major player in the smaller customer base segment. We grew from strength to strength and now have the equipment to compete with other large tube suppliers in most aspects including delivery times and pricing. Because we’ve kept our overheads to a minimum we are able to keep our overall production costs down and thus keeping the pricing to our customers at an affordable level.
We offer a comprehensive range of services and products designed to meet the specific and demanding requirements of the plastic tubes market. From inception of a design through to the manufacture and delivery, eMold is committed to full collaboration and consultation.
At eMold we will continue our policy of investment in new technology in order to meet the high standards required by our customers.

Our Contact Details
eMold Services cc

Tel.  : 011-8353693
Fax. : 011-8353698
Cel. : 082-4509490

Email :Send an Email

Physical address :78 3rd Street, Booysens Reserve 2091

Postal address    :PO Box 320, Linmeyer 2105

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