Sealed Air introduces the Instapak iMold® system, the only automated molding system available without a large capital investment. Producing between 400 and 600 cushions per shift, the system is ideal for low-volume packaging operations or decentralized high-volume operations. The iMold® system produces consistent, pre-molded Instapak® cushions using Sealed Air’s patented Foam Dispersion Technology™, which allows for a wide variety of cushion designs with varying shapes and sizes.
Using RFID technology, the system automatically identifies the mold and corresponding cushion recipe, ensuring that the iMold® system dispenses the correct amount of our Instapak®foam into the perfectly sized Instamate® film bag. Sealed Air’s patented Foam Dispersion Technology™ guarantees cushion consistency and integrity by dispensing Instapak® foam where it is needed most, eliminating material waste. The vacuum automatically draws the expanding foam-filled bag into the mold cavity, where the foam takes the shape of the mold. The vacuum shuts off and the cushion begins to cure. When curing is complete, the iMold® system ensures a quick release by automatically ejecting the cushion from the custom made mold. Cushions can be used instantly on-line, or transferred into bins for later use. 
The benefits of the Instapak iMold® system’s automated cushion production include reduced packaging material costs, increased productivity, improved product protection, increased storage space and a reduction of labor. “Labor is still a very large component to any operation,” said Tim McInerney, Sealed Air’s product manager for Instapak ® foam packaging. “Sealed Air is always looking for the opportunity to help its customers improve their bottom line.”