Foldable Crate Mould

Innovative foldable crate mould featuring living hinge technology. When empty, crates fold to 25% of original height, saving significant storage and transportation costs. Perfect for retail logistics and e-commerce.

Cycle Time

50-60 seconds

Mould Life

400,000+ shots

Material

Key Features

75% space saving when folded
Living hinge technology
Quick assembly/disassembly
High load capacity
Durable hinge design

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Technical Specifications

Product Size	600 x 400 x 280 mm (open)
Folded Height	70 mm
Mould Size	Multiple moulds required
Steel	718H / S136
Hardness	30-34 HRC
Runner System	Hot Runner
Ejection	Complex ejection system

Applications

E-commerce Logistics

Retail Supply Chain

Moving Services

Warehouse Storage

Revolutionizing Logistics Economics

Foldable crates represent the future of reusable packaging, and our moulds enable manufacturers to capitalize on this growing market.

E-commerce Logistics Revolution

A major European online grocery retailer calculated their empty crate return costs at €2.3 million annually. By switching to our foldable crate design:

Return transport costs reduced by 65%
Warehouse storage for empty crates reduced by 75%
ROI achieved in 18 months

The Economics of Space

Traditional crates occupy the same volume whether full or empty. Our foldable design transforms logistics:

Metric	Fixed Crate	Foldable Crate
Empty height	280mm	70mm
Truck return capacity	1x	4x
Warehouse footprint (empty)	1x	0.25x

Living Hinge Technology

The key to foldable crate durability is the living hinge. Our design survives 10,000+ fold cycles through:

Optimized hinge geometry
Material flow control during molding
Precise temperature management

Living Hinge Engineering: The Critical Success Factor

Understanding Living Hinge Failure

Living hinges fail through:

Molecular chain scission: Repeated bending breaks polymer chains
Stress whitening: Visible as white lines at hinge
Crack propagation: Final failure mode

Our Hinge Design Philosophy

We've developed proprietary hinge geometry that extends life by 3x:

Hinge Dimensions

Parameter	Industry Standard	Our Design
Thickness	0.5-0.6mm	0.35-0.4mm
Width	8-10mm	12-15mm
Radius	Sharp	0.3mm radius

Counter-intuitively, thinner hinges last longer because:

More uniform molecular orientation
Reduced stress concentration
Better heat dissipation

Mould Engineering for Foldable Crates

Foldable crates require multiple moulds:

Base mould: Bottom panel with hinge areas
Side wall moulds: Four side panels
Corner lock moulds: Locking mechanism

We offer these as a package with guaranteed compatibility.

Assembly-Ready Production

Unlike some competitors, our moulded components are ready for assembly with:

Pre-formed hinge creases
Self-locating corner features
Snap-fit assembly (no hardware needed)

Cycle Time Breakdown

Component	Cycle Time	Cavities	Hourly Output
Base	55s	1	65/hour
Side wall	35s	2	200/hour
Corner lock	15s	8	1920/hour

Why Choose Our Foldable Crate Mould

75% space reduction when folded

10,000+ fold cycle living hinge guarantee

No-hardware snap-fit assembly

Complete mould package with guaranteed compatibility

Frequently Asked Questions

Common questions about our Foldable Crate Mould

How many fold cycles can your foldable crates survive?

Our living hinge design is tested to 10,000+ fold cycles, equivalent to daily folding for over 27 years. In accelerated aging tests, hinges maintained 80% of initial strength at 10,000 cycles.

What is the space saving when crates are folded?

Folded crates are 75% smaller than open crates. Standard dimensions: 600x400x280mm open, 600x400x70mm folded. This means 4x more crates per return truck and 75% less warehouse space for empty crate storage.

Can the foldable crate support the same loads as fixed crates?

Yes, when open and locked, our foldable crates support 25kg internal load and 100kg stacking load (4-high). The corner locking mechanism creates a rigid structure equivalent to one-piece crates.

How many moulds are needed for the complete foldable crate?

The complete package includes 4 moulds: base panel, long side wall (2-cavity), short side wall (2-cavity), and corner lock mechanism (8-cavity). We offer this as a package with guaranteed dimensional compatibility.

Is PP or HDPE better for foldable crates?

PP is strongly recommended for foldable crates due to its superior living hinge properties. PP's molecular structure allows repeated flexing without fatigue. HDPE hinges typically fail within 1,000 cycles.