What is plastic?

Plastic is a polymer or chain of molecules with strings of carbon and other elements, made from petroleum by linking chemical reactions. There are so many different types with varying properties. Bio-based plastics are being researched and developed, but are not yet a feasible option in the toy business.

Thermoplastics such as Acrylic (Perspex), Acrylo-nitrile (Nylon), Polyethylene (Polythene), Polyvinylacetate (PVA), Polystyrene (PS) and Polyvinylchloride (PVC) soften with heat and harden when cold. They can be recycled and re-used repeatedly. We use thermoplastics in our products.

Thermosets such as Bakelite, Epoxy, Melamine, Polyester and Polyurethane are cured or hardened by heat, and cannot be re-used like thermoplastics.

Some plastics are spun into fibres, made into yarns and used for weaving into textiles or made into ropes; some can be sprayed as a coating, used as a glue, or used in paint. Plastics are used in toys because they are easy to shape and colour, they can be made soft or hard, flexible or stiff, they are good insulators, do not rust, are lighweight, cheap and durable.

Our products are often made from Polyethylene (PE) as it suits our products, methods and machines. We use other plastics according to the product requirements. PE is a relatively environmentally friendly plastic. There are different qualities, densities and types. For some purposes we can use recycled raw materials.

Additives are used in the plastic raw material to give various properties. Different plastics can contain all sorts of additives such as plasticisers or softeners, flexibility agents, fillers, reinforcement, pigments, flame retarders, antioxidants, blowing agents, lubricants, heat stabilisers, UV stabilization etc. etc. We often add colouring to the plastic mass as necessary.

Although we are aware of the regulations in most countries, it is always prudent to specify to us any special requirements or compositions, specific to the use of the product in your country, and whether any special testing, analysis or certification is required.

How is plastic shaped?

There are many different processing techniques commonly used in the toy and plastics industry. Most involve the use of a mould. Our factory uses the first two moulding methods.*

*Injection moulding: Plastic beads are melted under heat and shear energy and injected under pressure into a steel mould to give the required shape. The mould cavity is essentially a negative of the part being produced. Our factory uses this method predominantly.

*Blow moulding: Plastic material is forced into a closed mould and compressed air is used to blow a "bubble" inside the plastic. The plastic swells out like a balloon until it fills the mould and the required shape is obtained. We make dolls, soft and hollow toys using this method. (Plastic bottles can also be made this way.)

Rotational moulding: Plastic material is placed in a mould over a burner, and the mould is rotated to achieve a uniform wall thickness. Large hollow toys, water tanks and barrels can be made this way.

Extrusion: Hot molten plastic is forced through a nozzle to make pipes, tubes, jointing strips such as used in the building industry; and also large sheets that can be used later in thermoforming.

Blow extrusion: This is used for making plastic bags and films. An extruded tube with a sealed end is blown up like a balloon while still hot, stretching the plastic to make it thin.

Thermoforming: The plastic sheet is heated to near its softening temperature, and then pressure is placed on it with a male and/or female mould to produce a shape. This method is used to make trays, cups, masks and boards.

Vacuum forming: Sometimes pressure and vacuum are used in the thermoforming process and maximum uniformity of thickness and strength can be obtained. Packaging for biscuits and confectionery, cosmetics, disposable cups and containers for yoghurt can be made this way.

Slush moulding: This involves filling a hollow moulding with a solution of plastic material, heating the mould to gell an inner layer or wall of material in the mould, and then inverting the mould to pour out the excess liquid material. After cooling the finished part can be removed. This is used to make hollow objects.

Dipping: The mould is dipped into a plastic solution and the coating is fused to make the item. Soft flexible toys such as balloons, handlebar grips and flexible covers can use this technique.

Fabrication: Plastic sheets can be fabricated into tanks, acrylic signboards, and other industrial articles, by cutting, folding or bending and glueing.