How to create private silicone trays?
This article mainly introduces the advantages, production equipment, production process, etc. of silicone trays. If you want to create your own silicone tray brand or business, and have a clear understanding of the advantages, application areas, design, and production process of silicone trays, please go through this article. Silicone trays have the advantages of high and low temperature resistance -40-230°C, Recyclable, and environmental protection. They are widely used in kitchens, baking, beauty, personal care, and medical or industrial areas.
Logistics and transportation: The silicone pallet and tray have excellent anti-slip, shock absorption and protection functions, which can effectively fix items, reduce the vibration and sliding of goods during transportation, and ensure the safe transportation of goods. In modern logistics, transportation, warehousing and other fields, anti-slip silicone pallets or trays can also play an important role in saving costs, improving efficiency and promoting sustainable development. For example, the use of anti-slip silicone trays can reduce the use of packaging materials and reduce costs; at the same time, its anti-slip performance can also reduce the damage rate of items and improve efficiency. In addition, the environmental protection characteristics of anti-slip silicone trays also meet the requirements of sustainable development of modern enterprises, and can promote the development of environmental protection while ensuring the safety of items. Therefore, the use of anti-slip silicone trays is not only a simple logistics tool, but also a necessary choice for modern enterprises to achieve sustainable development.
Handling operations: Silicone pallets can be customized according to different shapes and sizes of items, and are more widely applicable. The anti-slip performance makes the handling process more stable and easier, especially suitable for low-rolling delivery and hand-held handling of pallets.
Baby food supplement: Silicone trays and placemats are made of food-grade platinum silicone, which is heat-resistant, cold-resistant, waterproof and dirt-proof. They are suitable as baby food supplement trays and placemats to ensure food contact safety.
Baking and handmade: Silicone trays are suitable for various purposes such as cakes, baked snacks, handmade soaps, etc. They are heat-resistant and cold-resistant in a wide temperature range and are suitable for use in ovens, microwave ovens, dishwashers, and refrigerators
What is the Silicone tray?
Silicone tray is a tray product made of silicone raw material. Silicone is a high molecular organic compound with excellent high temperature resistance, low temperature resistance, corrosion resistance and other characteristics. It also has excellent flexibility and elasticity. So the silicone tray which made from the silicone is suitable for use in various complex environments.
1. It can be the silicone Freezer Trays or ice cube tray used in kitchen refrigerators. They are great for Meal Prep, Freezing Sauces, Soups, make ice. Freeze and store soups, stews, sauces, and other foods in ideal portions. Remove, reheat, and use the exact amount you need. They can work even in -40 °
2. It can be the silicone tool tray part tray or rolling Tray for the handman. As they are no-slip and flexible.
3. It can be large square silicone tray mold is great for a variety of melt and pour or cold-process soap projects! They are also can cooking and baking the foods and meats as they can Withstands 230° high temperature.
Silicone tray are safe, BPA, PVC and phthalate-free，Lead free，convenient waterproof and easy cleaning, and hygienic kitchenware products, are reusable and prevent grease build-up.
Silicone tray mainly made of 100% food-grade silicone, which is soft, non-toxic, and high temperature resistant. non-stick. The silicone tray is Smooth inner surface: natural non-stick and easy to clean, can be kept clean and hygienic, and have a certain durability, and can accompany your cooking time.
The advantages of silicone tray
Silicone trays advantage are safe in material, flexible, not easy to deform or break; high in strength, can bear heavy objects; good in tensile strength, not easy to break; and have anti-slip, shockproof, moisture-proof, high and low temperature resistance and other features.
Safety Material: Z.S.R Silicone trays are made of 100% food-grade silicone material, which is non-toxic, odorless, does not contain harmful substances, and meets strict food safety standards. Even if they are in contact with high-temperature food for a long time, they will not release harmful substances.
Wear resistance and durability: Silicone material has extremely high wear resistance and impact resistance, is not easy to deform and break, and has a long service life. The surface of the silicone tray is smooth and will not scratch the items. At the same time, it has good anti-slip properties, which can ensure that the items are not easy to slip.
Easy to clean: The surface of the silicone tray is smooth, and it is not easy to adhere to food residues and bacteria. It is very convenient to clean. Just use warm water and neutral detergent.
High temperature resistance: Silicone trays have good high temperature resistance and a wide range of applicable temperatures (-40 to 230 degrees Celsius). They can be used in microwave ovens and ovens.
Environmental protection: Silicone material is recyclable, which reduces the environmental burden and is an environmentally friendly choice.
Design flexibility: Silicone trays can be customized in different shapes, colors and sizes according to needs, with high design flexibility.
Z.S.R offers various Custom silicone trays with different shape and colors for different industry used such as kitchenware, homeware, baby, Medical ,Promotional etc .
Silicone Trays
Materials, Tools, Equipment
According to the molded products making process, there are 5 ways of silicone molding process: silicone rubber compression molding, LSR injection molding, silicone Drip molding, silicone Extrusion Molding, silicone Calendaring molding. Here in Z.S.R, For silicone trays, we only have 4 molding process capacity. The different molding process need the different material, tools and equipment:
Silicone compression molding
Silicone Compression Molding
The main materials required for the production of silicone trays include silicone raw material, crosslinking agent, catalyst, filler and additives. These materials working together to get the silicone trays. Usually, silicone rubber raw material, crosslinking agent and filler are made into one component, and catalyst is a separate component. Therefore, mold silicone products is also called two-component vulcanized silicone products. In Z.S.R, All the silicone raw material we used is FDA or LFGB approved 100% Food Grade silicone rubber. The crosslinking agent, catalyst is Platinum if you needed.
Material preparation: Choice the correct standard material according to your products function and test standard, such as FDA or LFGB material. Then
Silicone rubber mixer: The silicone rubber material mixer is used to mix the raw materials with additives such as vulcanizer and color paste. used to add vulcanizer, masterbatch and other auxiliary materials to the raw materials, and refine the raw rubber into usable raw rubber. Z.S.R have 2 Silicone rubber mixer workshop and machine to mixed the material for your silicone trays.
Silicone Rubber cutter: cuts the refined silicone trayerial into the required size and weight for making products. Z.S.R have 2 silicone rubber cutting machine to cut the material for your silicone trays.
Electronic scale: Weight the cutted silicone rubber mixed material to ensure that the product is within the error range. We have more than 60 Electronic scales for each silicone compression molding machine.
Mold preparation: Before the silicone trays making, Make the corresponding mold according to the product design requirements. The shape and size of the mold determine the shape and size of the product. The mold material is usually Steel or aluminum alloy (prototype tooling). Z.S.R International Group (HONG KONG) CO., LIMITED in-house tool shop consists 6 sets of advanced CNC machining centers and 3 sets of EDM spark machines for tooling; So, we can make most of the silicone tray tooling and repair the silicone tray tooling in our factory to catch up your time needed. The complete mold work shop can help you develop your new design silicone products and offer the creative silicone trays OEM & ODM service for you.
Molding stage: Install the prepared mold on the vulcanizer to ensure that the mold fits well and is well sealed. the hydraulic compress molding machine (also known as the flat vulcanizer) provides the pressure, mold temperature and vulcanization time required for molding; After the mold is heated to the appropriate temperature, the prepared silicone raw material is placed in the mold for molding. During the molding process, parameters such as temperature, pressure and time need to be controlled to ensure that the product is molded completely and the size is accurate.Z.S.R have 32 sets silicone rubber molding machine to molded your silicone products.
The sandblasting machine is used to clean the molding mold and keep the production process clean.
Post-processing: The silicone trays need to be post-processed such as deburring, cleaning, and drying to improve the appearance quality and durability of the product.
Quality inspection: Quality inspection is an important link to ensure the quality of silicone products, including appearance inspection, size measurement, performance testing and other aspects. Only products that have undergone strict quality inspection can be shipped out of the factory.
Packaging and shipment: Products that have passed quality inspection need to be packaged and shipped. The selection of packaging materials should comply with relevant standards and requirements to ensure that the product is not damaged during transportation.
Z.S.R one day mass production capability for 15000-59999/pcs silicone trays according to the structure and size with the 32 sets molding machines.
Contact Z.S.R to create your own silicone trays.
Would like to know more about silicone compression molding or how to make molded silicone rubber products, check Silicone compression mold.
L.S.R injection molding
Liquid Silicone Rubber (LSR) Injection Molding
Liquid silicone injection molding mainly uses liquid silicone rubber (LSR) material. LSR is a two-component thermosetting material, usually mixed in the form of A/B components. Component A contains a platinum catalyst, while component B contains a cross-linking agent. LSR is in a liquid state before curing and becomes an elastomer after curing.
Material preparation:
Choose the appropriate liquid silicone type based on a comprehensive assessment of the product’s purpose, properties, shape, etc. For example, the medical industry should choose medical-grade silicone trayerials, and infant products generally use highly transparent food-grade liquid silicone raw materials. Prepare the appropriate color paste so that it can be mixed to achieve the final LSR molded product color that customer needed.
Mixing equipment: It is used to mix the liquid silicone of components A and B to ensure accurate proportions and uniform mixing. Common mixing equipment includes static mixers and vacuum tanks, etc.
Vacuum pump: used to remove bubbles from liquid silicone to ensure that the surface of the molded product is smooth and flawless.
Mixing container and stirring rod: containers and tools used to mix liquid silicone to ensure uniform mixing
Mold preparation
Silicone Injection Mold: The mold is the carrier for liquid silicone injection molding. Its design and manufacturing must consider factors such as the fluidity of silicone, shrinkage after solidification, and the shape, size and wall thickness of the product. The precision and durability of the mold have a direct impact on the quality of the final product. Z.S.R have 12 experienced engineer will consider your molded LSR products structure and design your silicone injection mold with the correct parting line and gate. Then Z.S.R team will make your precision injection tooling in our one roof mold workshop.
Injection molding machine: The injection molding machine is the core equipment for liquid silicone injection molding, which is used to inject the mixed liquid silicone into the mold. Common types of injection molding machines include vertical injection molding machines and horizontal injection molding machines. Vertical injection molding machines are suitable for small-batch production and automatic molding of complex products, while horizontal injection molding machines are suitable for large-scale production, especially in the production of products that require high precision and smooth surfaces. Such as silicone baby nipple, baby pacifier or silicone medical products. The mold needs to be preheated to 170~200℃, and the liquid silicone is injected into the mold through the injection molding machine. The injection pressure and temperature need to be precisely controlled.
Curing: Liquid silicone undergoes a curing reaction at high temperature, and the catalyst accelerates the curing process
Demolding and post-processing: The cured LSR silicone trays needs to be demolded from the mold, and some products may also require post-curing treatment, cleaning and removal of impurities.
Quality control: Products must undergo strict quality inspections, including tests on size, hardness, transparency and elasticity.
Packaging and transportation: Products that pass quality inspections will be cleanly packaged and shipped to the location specified by the customer.
Z.S.R own 7 sets LSR injection molding machine to put your LSR silicone trays on mass production.
Z.S.R one day mass production capability for 10000-69999/pcs silicone trays according to the structure and size with the 7 sets molding machines. Liquid injection molding is very friendly to silicone products with high precision, high requirements and large-scale production to ensure product consistency, and is the most suitable choice.
Want to know more information about LSR molding or how to make L.S.Rmolded silicone rubber products,: check Liquid silicone rubber lsr injection molding.
Contact Z.S.R to create your own L.S.R silicone trays.
Silicone Dripping dispensing molding
Multi-Color Dripping Molding
Need prepare silicone as the main material for dispensing molding, usually liquid silicone (LSR) and solid silicone, color paste, vulcanizer, and also need silicone vacuum machine and automatic dispensing machine. As this kind of molding have two kind of molding process. We also call them co-injection molding. Mixed L.S.R material dripping from the automatic dispensing machine first, then heat and curing. Put the solid silicone rubber material on and close the molds put them silicone vacuum machine Vulcanization molding.
L.S.R Material prepared
Choose the appropriate liquid silicone type based on a comprehensive assessment of the product’s purpose, properties, shape, etc. For example, the medical industry should choose medical-grade silicone trayerials, and infant products generally use highly transparent food-grade liquid silicone raw materials. Prepare the appropriate color paste so that it can be mixed to achieve the final LSR molded product color that customer needed.
Solid silicone material prepared
Silicone rubber mixer: The silicone rubber material mixer is used to mix the raw materials with additives such as vulcanizer and color paste. used to add vulcanizer, masterbatch and other auxiliary materials to the raw materials, and refine the raw rubber into usable raw rubber. Z.S.R have 2 Silicone rubber mixer workshop and machine to mixed the material for your silicone trays.
Mixing equipment: It is used to mix the liquid silicone of components A and B to ensure accurate proportions and uniform mixing. Common mixing equipment includes static mixers and vacuum tanks, etc.
Vacuum pump: used to remove bubbles from liquid silicone to ensure that the surface of the molded product is smooth and flawless.
Mixing container and stirring rod: containers and tools used to mix liquid silicone to ensure uniform mixing.
Silicone Rubber cutter: cuts the refined silicone trayerial into the required size and weight for making products. Z.S.R have 2 silicone rubber cutting machine to cut the material for your silicone trays.
Electronic scale: Weight the cutted silicone rubber mixed material to ensure that the product is within the error range. We have more than 60 Electronic scales for each silicone compression molding machine.
Mold preparation
Mold: The mold is a key component of drop molding, usually made of aluminum mold, brass mold, electroplating or silicone mold. The design and production of the mold have an important impact on the quality and appearance of the product. The Z.S.R team has rich experience in making silicone drop molding molds, from Bing Dwen Dwen colorful ribbons to Disney characters, they can be perfectly reproduced.
Drop molding machine: This is the core equipment for silicone drop molding. It is mainly used to move the dispensing needle of LSR material that has been vacuum scheduled to the specified position of the drop molding mold, and control the amount of dispensing by controlling the time of extruding the paste resin and the speed of the needle moving. The drop molding machine is mainly composed of two parts: the control system and the machine structure. Commonly used control systems include LOGOSHOP, CRS-DriptMold, etc.Adjust the glue dispensing speed, glue dispensing position and glue dispensing thickness of the glue dispenser according to the requirements of the product. Ensure the normal operation and glue dispensing effect of the glue dispenser. After debugging, conduct a trial run to ensure that the glue dispenser can work stably and accurately.
Molding stage: Place the mold under the glue dispenser, control the glue dispensing position and speed of the glue dispenser, and accurately drip the silicone mixture onto the mold. According to the needs of the product, glue can be dispensed multiple times until the required thickness and shape are achieved.
Heating equipment for silicone curing: During the drop molding process, heating is required to make LSR resin react chemically and become solid. Therefore, heating equipment is essential. Place the glued product in a constant temperature area to cure the silicone in few minutes.
Second Molding stage: Put the cutted mixed solid silicone rubber material on the curred LSR, then closed the mold and put the mold to hydraulic compress molding machine (also known as the flat vulcanizer) provides the pressure, mold temperature and vulcanization time required for molding; The vulcanization temperature and pressure are adjusted according to the silicone raw material and product requirements. Z.S.R have 16 sets silicone dripping molding line to molded your multi-colored silicone products.
Cooling and demolding: After the vulcanization is completed, remove the mold from the vulcanizer, open the mold after cooling to room temperature, and take out the silicone tray.
Post-processing: The silicone tray is trimmed, deburred, and other treatments are performed to achieve the ideal shape and surface quality.
Z.S.R own 16 sets dripping molding line to put your multi-colored silicone trays on mass production.
Z.S.R one day mass production capability for 12000-39999/pcs silicone trays according to the structure and size with the 12 dripping molding lines. Silicone dripping molding is very friendly to silicone products with multi-colored, 3D effect, IP and cute products to ensure the products with colorful and 3D effect without post printing.
Contact Z.S.R to custom your multi-colored cute silicone trays products.
Would like to know more about co-injection dripping molding or how to make multi-colored silicone molded products, check:Co injection dripping molding.
The customization process for create your private silicone trays
In Z.S.R, we can custom the silicone trays shape, size, color, pattern, brands, logo by silkscreen printing, full-color printing, or laser engraving for your silicone products, if you would like to custom your brands silicone trays contact Z.S.R.
Customizable Content:
Appearance (shape, color): The silicone trays shape can be round, square or creative shape by developing the new tooling. The color can be white, blue, black or use the pantone book number to customized. You also can get mixed color, marble color or double colored, multi-colored appearance.
Material properties: You can customization the material with HTV material or LSR material. The hardness you can choice from 5-80 shore A, Translucent to highly transparent, Safety level from Food Grade to Medical grade, tensile properties from ordinary to high level)
Mold type: Steel, Copper or Al.
Molding method：LSR Injection molding, HTV compression molding, dripping molding.
Labeling: Logo on the tooling and get the logo products. We also can Screen Printing，Laser Engraving，Heat Transfer Printing your logo on the silicone trays already.
Packaging：zip bag, back card PET box, color box.
Shipping method: DHL, FedEx, Air shipping or Sea shipping.
How to create your silicone trays brand or start your silicone trays business?
1. Choose the design and style of the silicone molded products that you want to customize from Z.S.R’s existing designs. Or Starting with your new product idea to create your molded products, our engineers can proceed with the CAD/Stp/Step/X-T drawings just based on your sketches.
Our design and manufacturing engineers will work with your team to ensure designs meet processing requirements and can be produced consistently and cost-effectively. For your ODM or OBM project, we can sign an NDA non-disclosure agreement with you. It wards off any copycats that plagiarize your designs.
Design 3D structure of the silicone tray according to your idea.
2. Z.S.R will make the prototype tooling to get the prototype to let you confirm. If all go through, we will make the mass production tooling for you and remake the samples for get your approved confirmation samples.Make the silicone tray tooling according to the silicone tray design requirements (Signal color or multi color) use the different metal, such as steel, copper or AL to ensure the accuracy and durability of the tooling.
Z.S.R International Group (HONG KONG) CO., LIMITED in-house tool shop consists 6 sets of advanced CNC machining centers and 3 sets of EDM spark machines for tooling; So, we can make most of the silicone tooling and repair the silicone tooling in our factory to catch up your time needed.
3. Prepare the silicone raw material: Raw materials are the key to silicone trays products. Usually, Silicone trays meet certain environmental protection standards, so silicone materials are no exception. Normally, environmentally friendly Fumed silicone rubber is selected for customized processing, while many manufacturers use Precipitated silicone rubber for processing. Although the product is not greatly affected, it is still different Fumed silicone rubber from in quality after a long time. Mix the silicone color according to your silicone tray needed. Cutting the mixed silicone material in the correct weight.
4. Feeding the prepared silicone mixed material on-no matter Liquid siilcone rubber or solid siilcone rubber in to the mold.
5. Curing the silicone tray: The silicone material is feeding into the mold after mixing, and the silicone material is filled into the entire space of the mold through heating and pressure. The temperature, pressure and time control of the molding process directly affect the size, shape and quality of the product.
No matter the silicone tray was made by: Compression molding or silicone dripping molding or LSR molding.
6. Demold: After the curing is completed, take the silicone tray product out of the mold.
7. QC the silicone tray: Quality inspection: Visually inspect the molded silicone tray to see if there is lack of material, uncooked Ness, or impurities.
8. Post-processing: Carry out the silicone tray and then do the post processing and treatment, such as trimming, grinding, polishing, spraying, inspection, etc.
9. Secondary vulcanization: Secondary vulcanization is a process that must be handled for any product that has passed the inspection. The main reason why infant silicone products have a certain smell is that they have not been subjected to Secondary vulcanization baking, and the catalyst of the raw materials of the products has not been emitted. At present, many silicone children’s product manufacturers basically handle it, but the time and temperature of the Secondary vulcanization treatment are different. Bake in oven 2-4 hours to meet FDA or LFGB Standard. LSR silicone tray may do not need this process.
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10. LOGO or Pattern printing if needed: screen printing or laser engraving. Most of time, we put the silicone tray logo on the silicone tooling directly. Check the products branding service to know more.
11.Final Quality control and testing: After all the silicone tray making process finished, we will arrange the final QC for the silicone tray before the delivery.
12. Package and Warehouse: Z.S,R offer custom packaging solutions you need for all your product packaging. Our custom packaging includes paper boxes, PE/PVC boxes, printed labels, hangtags, barcode stickers, etc to protect the safety of the product during transportation and storage, while ensuring the safety and aesthetics of the product.
In Z.S.R,we manufacture the silicone tray according to the client’s design and idea. We try our best to deliver the quality silicone tray to our customer.
Notice
When you buy the silicone tray, should pay attention to:
- With the Certification: The silicone tray should be is lead, PVC-, and phthalates-free. Check whether the silicone tray product has a safety test certificate to ensure that it meets the relevant food safety standards. In China, silicone tray products can be checked for compliance with the limit requirements of GB 4806.11-2016 “National Food Safety Standard Food Contact Rubber Materials and Products”, while foreign products should be checked for US FDA certification, CPSIA certification or EU LFGB certification, etc. Food-grade silicone is preferred, IN USA -FDA Approved -silicone tray. The silicone tray should be 100% food-grade silicone raw materials to ensure safety. Ensuring that it complies with FDA and LFGB standards. Avoid choosing silicone tray made of ordinary plastics because they may release harmful substances.
- Quality and size: High-quality silicone products usually have a smooth surface and no obvious defects. When purchasing, you can make a preliminary judgment on the quality of the product by observing its appearance and feel. And Consider size and capacity. Choice the correct size silicone trays.
- Brand selection: Choose a brand with technological research and development and a good reputation to ensure product quality and safety. Avoid buying products made with inferior raw materials to reduce safety risks.
- Pay attention to environmental certification: Choose silicone dinner plates that have passed environmental certification, which are both safe and environmentally friendly, adding points to your health.
- Cleaning and Sterilization: silicone tray is easy to clean and able to withstand high-temperature disinfection to maintain hygiene. but be careful to avoid leaving it static in a high-temperature oil pan for a long time to avoid deformation. It should be cleaned in time after use to maintain its hygiene and durability
When you would like to buy the silicone tray, you should comprehensively consider factors such as safety, material, design, brand, cleaning and maintenance, and size to ensure a safe.
Conclusion
No matter you would like to create the silicone tray with your logo or design for sales, promotional or events. Our high-quality customize silicone trays are perfect for branding, souvenir , corporate gifts.
Z.S.R. customized branded silicone tray with added your logo, design pattern, text may be your good choices.
In Z.S.R, all the steps from raw silicone trays material selection to molding, curing, and quality control, each step plays a vital role in creating your silicone tray that meet safety standards and perform well in their intended applications.
Contact Z.S.R to brand your own silicone tray by contract manufacturing.
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About Author: Z.S.R International Group
Z.S.R International Group(Hong Kong) co., Limited, is a one-stop supplier for molded silicone products and silicone products molding solution provider in the consumer products field. We offer OEM services from silicone product design to Silicone products contract manufacturing. We have the capability for custom silicone tooling, LSR(Liquid silicone Rubber) molded silicone products, solid silicone molded products, molded silicone multi-colored products. We also can custom molded silicone, custom molded LSR, custom molded dripping injection dispensing(co-injection) silicone multi-colored products.
