Plantopia: How It's Made - Part 2

 This article is the second in a series of two explaining how the process of making a Plantopia hanging basket is done - from raw material to finished product. 

We left off at the Plantopia pot being manufactured in the plastic injection molding machine. The plastic resin is heated so that it melts and then is shot into a steel mold, where it then cools.

After this cycle is completed many times, you end up with a slew of raw Plantopia flowers that are stacked onto a pallet for secondary operations. Sometimes, the secondary operations are done right at the machine to fulfill an order or build up specific SKU. Other times, they are left raw on a skid until it is determined where the final landing spot the Plantopia hanging needs to go before shipping out the door.

Secondary Operations

12" Pots getting ready to be punched

 Each 12" Plantopia gets punched at the bottom to create a drain hole. This makes sure that there is never too much water sitting in the basket. After each pot is punched, it is ready to be finalized for an order. Our 14" pot already has this feature built into the mold. To produce the 12" more reliably, the hole is molded closed and punched after. The little things we learn as plastic injection molders.

Fulfillment

Plantopia Hanging Baskets can go in a variety of directions - in small pack sizes for internet orders, into retail packs - either a 12 ct. case or a 25 pack display or into a grower path.

Our 12" Stone Pot with its Retail Packaging Label

Retail Packaging  

Retail Plantopias are packaged with the panels inserted into the pot with a shelf label to communicate the features to the consumer.  The shelf label contains instructions on the back and a baggie with chain is glue to the inside bottom of the pot. They are then packed into either a 12 ct. case or 25 ct. display pack. 

Plantopia Pot Getting Assembled for Retail. 

Grower Path 

Plantopia was invented by a grower and produces massive results when grown up. We offer bulk pots that are placed onto a pallet with the panels left out to reduce the labor for the grower. We substitute wire for chain - wire doesn't fall into the pot whereas chain collapses. We fit anywhere from 1000 to 1200 pots on a pallet depending on the size of the pot being shipped. 

An Internet Order Getting Packed

12 ct. Case of Retail Plantopia

25 ct. Plantopia Displays Staged to Ship

 So, there you have it! From raw, recycled plastic resin to the final shipping stage, that is essentially what goes into getting a Plantopia Hanging Basket ready for the end user. We have been making plastic injection molded products since 1989 and are a family-owned company. You can find out more information about our company here: www.gaimplasticsinc.com 

Visit www.plantopiaflowerpotswww.plantopiaflowerpots.com.com for more information about Plantopia, how to order and great growing ideas!

How It's Made - PLANTOPIA

Plantopia Hanging Baskets are quality, durable plastic flower pots made from recycled plastic resins right outside of Chicago. Made using the injection molding process by G.A.I.M. Engineering - family-owned company manufacturing since 1989, Plantopia goes through a multitude of steps before being released into the market - either to a retailer or wholesaler, direct to consumer or to a grower.

The most important part of a plastic product is the tooling or mold as its called. Created from a block of steel by one of our local U.S. vendors, it goes through a rigorous creation process using a variety of high-tech and high-quality machines and tools to develop and create the final tool. All this is done after taking an idea or concept, creating blueprints and prototypes before finally being produced. This could take 6 or more weeks to finally have a tool ready to sample before production begins.





Once the tool is made, sampled and enhanced for production, it's time to make some parts! Pictured to the right is a lot of recycled resin used to eventually make a Plantopia flower pot. The resin we use is fed through what is essentially a vacuum tube which loads it into the injection molding machine (left). This puts the plastic resin into the machine automatically to increase production efficiency.



Plastic injection molding is basically the same process used to make popsicles - albeit at much different temperatures. To make yummy popsicles, add some flavored sugar water into some sort of plastic mold and put into the freezer. Allow it to freeze and voila! - an easy way to make a special treat. Molding plastic is similar. In this case, the injection molding machine heats up the plastic - usually over 400 degrees or more depending on the type of plastic - until it's a liquid. It is shot into the steel mold to take the shape of the part and then cools. Once cooled, the mold opens and releases the part. That's it. The whole process of injection molding a part can typically take anywhere from 20 seconds to 90 seconds depending on the part and resin being used.

"That's it," you ask. Well, not quite. Our next blog post will explain what happens after the parts are taken from the machine and put into the next phase. Check back here to see the completed process of how a Plantopia Hanging Basket is made! Post your questions or comments below.