At Pack Expo Las Vegas, Dordan Manufacturing Company Inc. will introduce a new exhibit that demonstrates collaboration with natural material supplier Ecovative. Ecovative “grows” EPS-like packaging material out of agricultural waste utilizing the biology of fungal mycelium to “bind” the fibers together. While Ecovative first applied this technology to the packaging industry by supplying custom-designed protective packaging, they now offer several stock packaging/products, including the recently designed EcoCradle® insulated shipping cooler.

Ecovative approached Dordan in early spring with the design of the cooler, which consists of several panels that, when folded and placed inside a corrugate box, make an insulating and protective shipping container. During the “grow process,” Ecovative utilizes thermoformed “grow trays” that serve as the molds in which their material is formed into product over a seven-day period. Ecovative enlisted the design and manufacturing services of Dordan due to its reputation of sophisticated custom design and experience in applying the art of thermoforming to unique applications.

John Kreider, Dordan’s head Engineer, worked with Ecovative’s design engineer, Sam Harrington, on the design and manufacture of their Cooler Grow Trays. Ecovative looked for a standardized tray format to allow for easy and consistent integration into their custom filling and washing stations. After much dialogue into the requirements of their process, Dordan and Ecovative developed a design that allowed for tray rigidity based on the parameters of their processes, while producing a quality, consistent part for Ecovative.

Harrington explains, “These grow trays were a great chance for us to experiment with some new geometries and new growing techniques, in order to produce an exciting product that a lot of people have been calling asking for: coolers.”

Dordan Manufacturing will display this collaboration with Ecovative by displaying the Cooler Grow Tray with EcoCradle “growing” inside.