Combination of supercritical fluid and original forming technology enables a 30% reduction in thickness, enhancing environmental performance while maintaining strength.

Samples of Toppan’s new ultra-thin-walled injection molded containers
©Toppan Printing Co., Ltd.

Tokyo – February 24, 2021 – Toppan Printing (Toppan) (TYO: 7911), a global leader in communication, security, packaging, décor materials, and electronics solutions, has used supercritical fluid1 and its original molding technology to develop an ultra-thin-walled container roughly 30% thinner than conventional injection molded plastic. The new container is an addition to Toppan’s “SUSTAINABLE-VALUE™ Packaging” lineup, which is part of the recently launched “TOPPAN S-VALUE™ Packaging” range targeting added value for society and fulfilling living. Samples will be made available in Japan from February 24 for manufacturers in the foods and toiletries sectors.

The Sustainable Development Goals (SDGs) and other initiatives aimed at environmental preservation and resource saving are gaining momentum on a global scale. The problem of marine pollution caused by plastic waste has prompted a focus on packaging with reduced environmental impact. Reduction of consumption of plastic resin for injection molded containers, however, requires the minimum possible thickness when molding is performed and has presented challenges in terms of costs, durability, and the feasibility of mass production. Thermoforming has generally been considered better for producing containers that need thin walls, but it does not offer the same scope of possibilities for design as injection molding.

Toppan has developed a new technology making it possible to exceed the conventional limit of injection molding and form products with a reduced thickness close to that achieved by thermoforming. Supercritical fluid is dissolved in molten resin to ensure that it efficiently reaches every corner of the injection mold. This means lighter containers with thinner walls can be produced while ensuring freedom for shape and design.

Due to the combination of supercritical fluid and Toppan’s original molding technology, the thickness of the wall of injection molded items can be reduced by approximately 30%, from 0.5 mm to 0.35 mm. This makes it possible to reduce plastic consumption by up to 30% and also helps to lower CO2 emissions associated with resin manufacture. In the case of a prototype margarine tub, CO2 emissions during manufacturing decreased by about 20%.

As fluidity of the resin injected into the mold is improved, the technology also enables the use of more eco-friendly plastics, such as biodegradable resin and biomass polyethylene, which have previously been difficult to mold. Despite the reduction in thickness, strength is maintained, as is the scope to design containers in a wide range of shapes matched to their use.

Comparison of sample using conventional injection molding technology (left) and Toppan’s new ultra-thin-walled injection molded container (right)
©Toppan Printing Co., Ltd.

“This new technology enables the production of containers that offer all the benefits of conventional injection molding but with reduced impact on the environment,” said Toshiaki Kakemura, General Manager of Plastic Development in Toppan’s Packaging Solutions business. “We will expand sales to manufacturers of food and toiletries and continue to drive sustainable solutions for society and growth for our customers’ business through the TOPPAN S-VALUE™ Packaging range.”

The ultra-thin-walled injection molded container will be on display in the Toppan Booth (S1-12, South Hall 1) at TOKYO PACK 2021, which will be held at the Tokyo Big Sight exhibition center from February 24 to 26.

1. A supercritical fluid is a substance at a temperature and pressure above its critical point that has both gas and liquid properties.

About TOPPAN S-VALUE™ Packaging

With TOPPAN S-VALUE™ Packaging, Toppan aims to contribute to a better society as well as fulfilling, comfortable living through packages that offer more value. SMART LIFE-VALUE™ Packaging provides value for people, SOCIAL-VALUE™ Packaging drives value for society, and SUSTAINABLE-VALUE™ Packaging creates value for the Earth.
People / SMART LIFE-VALUE Packaging
Solutions that function as a medium for communication to maximize the customer experience. Toppan provides optimal value for various aspects of everyday life, enabling smooth purchasing, efficient storage, preparation of tasty food, easy disposal, safety, peace of mind, and more.
Society / SOCIAL-VALUE Packaging
Packaging and services generating value that helps to sustain business activities by enhancing efficiency in the supply chain, raising productivity, optimizing sales, and providing solutions to wide-ranging challenges.
Solutions that help drive reduction of environmental impact and create a circular economy. Toppan offers packaging using recycled plastic, mono-material packaging that enhances recyclability, and packaging using plant-derived materials such as paper and biomass plastic.

About TOKYO PACK 2021

Dates: February 24 to 26, 2021
Time: 10:00–17:00 (visitor registration from 9:30)
Venue: Tokyo Big Sight, West Hall 1-4 and South Hall 1-2
Theme: Working Towards a Healthy Planet
Organizer: Japan Packaging Institute
Official website:
Toppan online exhibition website: 

About Toppan

Toppan is a leading global provider of integrated solutions in the fields of printing, communications, security, packaging, décor materials, electronics, and digital transformation. Serving customers in every sector of business and industry, Toppan’s global team of more than 50,000 employees offers optimal solutions enabled by industry-leading expertise and technologies to address the diverse challenges that businesses and society face in today’s rapidly changing market.

For more information, visit or follow Toppan on LinkedIn

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