Customer Spotlight: How PlantSwitch Brought Compostable Plastic Cutlery to Market

What Is PlantSwitch and What Challenge Did They Bring to Husky?

PlantSwitch, an ambitious American startup, was aiming to replace petroleum-based single-use plastic with plant-based alternatives. The company contacted Husky in 2022 to learn more about injection molding options for a line of innovative bio-plastic cutlery. 

The core challenge: PlantSwitch had limited experience in both the market and injection molding processes. Molding with bioresin requires deep processing knowledge to produce a high-quality part consistently, and that expertise gap needed to be closed before production could begin.

How Do You Mold Bioresin for Compostable Plastic Cutlery?

PlantSwitch knew that reaching their goal of becoming a leading bioresin-based cutlery manufacturer would require working with an experienced injection molding partner. Husky collaborated closely with their leadership team to develop a plan that included lab trials and a series of business cases, giving PlantSwitch a clear picture of the full investment required.

“Understanding that the market is shifting due to various legislative requirements around single-use plastic, along with a consumer shift towards a more environmentally friendly solution, we saw an opportunity to leverage our bioresin technology and focus our efforts on providing the highest-quality home compostable resin. Using this resin, we developed a project in collaboration with Husky to produce industry-leading compostable cutlery," said Dillon Baxter, CEO and Co-founder of PlantSwitch.

PlantSwitch and Husky ran lab and analysis trials to test how the plant-based resin behaves in an injection process. The resin showed strong results using Husky hot runner technology. With consumer demand for home-compostable products continuing to grow, those results led to a revival of the original cutlery concept and the development of new cutlery design.

What Solution Did Husky Recommend for Bio-Plastic Cutlery Molding?

Based on the trials and business case analysis, Husky recommended an integrated solution tailored to the application: a HyLECTRIC® packaging molding system for high-cavitation cutlery production, paired with UltraMelt™ hot runner technology for precise bioresin melt delivery.

What PlantSwitch Achieved with Husky's Injection Molding Technology

Armed with the HyLECTRIC® system and UltraMelt™ hot runner, PlantSwitch secured a significant order from a leading American supermarket chain for a line of plant-based cutlery, establishing themselves as a manufacturer and supplier in the compostable cutlery market.

The company is now exploring the production of compostable coffee pods, showcasing their commitment to sustainable and environmentally friendly packaging alternatives.

“PlantSwitch stands at the forefront of the eco-conscious movement, and our collaboration with Husky has paved the way for a transformative impact, proving that when done right, it’s possible for sustainability and economic viability to go hand in hand. Together, we're not just creating products; we're shaping a greener, more resilient future,” Baxter said.

How Husky Supports Injection Molding Projects End-to-End

Husky is a dedicated single-source provider, integrating injection molding systems with deep application expertise, comprehensive guidance, and a holistic approach to customer success.

Support spans every phase of a project, from concept to completion:

• Strategic application planning and consulting
• Expert engineering and design assistance
• Turnkey advisory services and project management
• In-depth materials expertise
• Advanced simulations covering mechanical, thermal, and rheological aspects
• Prototyping, testing, and scale-up solutions
• Continuous 24/7/365 production monitoring through Husky Advantage+Elite™
• A global sales, parts, and service network

HyLECTRIC® Systems: Built for High-Cavitation Bioresin Molding

Bioresins are sensitive materials that require specific melt preparation conditions. Husky HyLECTRIC® packaging molding systems are adapted to meet those requirements, with modified extruder and melt stream delivery components that enable high part quality and a wide process window.

Clamping Performance & Cycle Time

HyLECTRIC® systems are designed to support aggressive cycle times across a wide range of applications. Key features include:

• Reflex™ platen: Enables uniform clamping force distribution across the entire moulding surface, supporting part-to-part consistency
• Superior tonnage distribution: Reduces clamping force and mould wear while maintaining high part quality on long-term runs
• Wide tie-bar spacing, large platens, and a stiff clamp base: Enable the system to run heavy, high-cavitation moulds at aggressive cycle times

This combination of features makes HyLECTRIC® well-suited to plastic cutlery molding.

Connectivity, Control & Flexibility

The latest generation HyLECTRIC® systems build on previous generations with enhanced capabilities in connectivity, control, energy management, and operator experience. The result is a system that delivers strong productivity, versatility, and ease of use.

To meet varying performance requirements, HyLECTRIC® systems are available from 120 to 1,200 metric tons with a broad selection of injection units. Longer clamping unit versions are available for large shut-height tools.

UltraMelt™ Hot Runner System: Precision Melt Delivery for Bioresin Applications

Husky's UltraMelt™ is a premium melt-delivery system designed for applications that require precise process and thermal control with minimal effect on resin chemistry. Developed using dozens of different test manifolds, it is specifically engineered to produce small parts from materials that are sensitive to temperature and chemical reaction. Key design features include:

• Aerospace-grade materials: Preserve the sensitive chemistry of bioresin and minimise corrosion
• Balanced melt supply manifold: Delivers consistent pressure and melt volume to each mould cavity
• Valve gate nozzle: Maintains best-in-class gate quality and supports extended mould life
• Configurable gate methods, nozzle sizes, and actuation styles: Available for both low and high-cavitation moulds

All UltraMelt™ components are designed with cost of ownership in mind, featuring extended maintenance intervals that enable maximum service life over the long term.

NEXT STEPS

Speak with a Husky molding expert to learn how our latest technologies and expertise can enable your application and business growth.