a strong family with a superior features - packplus.in · 2+2 mould container + lid family product...

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Technology working for youTechnology working for you

A strong family with a Superior features !

Your partner in Automation

Leading & Specialist in Plasticequipments manufacturing:

Water Flow Regulators,Temperature Controllers,Robots & Automation,Compact & Central Dryers,Integral and Central Vacuum Loaders, Granulators ,Volumetric and Gravimetric BlendingIn Mold labeling Molds IML – Robots Injection Molding Machine

Global presenceGlobal presence : 63 Countries : 63 Countries

Manufacturing Manufacturing : 9 facilities globally: 9 facilities globally

Wittmann Battenfeld , Austria

Global Headquarter: Wittmann , Austria

Wittmann – Manufacturing Units

Plant 2: Vienna, Wittmann :HungaryWittmann -germany Wittmann -France

Wittmann - China Wittmann -USA Wittmann -Canada Wittmann Battenfeld–Germany

IML- Video

IML (In-Mold-Labeling) Application Areas.

Paint Container Food Packaging

Drinking cups Customized

Margarine, butter, ready-to-eat meals, salads

Personal care

Paint, chemical, home repair * Pail also can be used for catering

IML- APPLICATIONS

Outdoor furnituresChair with advertising Dustbins

High resistance UV

Automotive partsInside / outside

Effect of wood or metal

Technical parts for long time printingCrates

Resistance to many thousand of washing cycle

IML- APPLICATIONS

It’s the insertion of pre-cut printed labels into a mold during the molding process

Parts are produced and decorated in one stepAll post-mold labeling operations, equipmentand costs are eliminated

Decoration is imbedded in the product wallVery durable and nearly impossible to remove

Printing quality

With IML colours can be added

onto

your products

IML- DEFINITION

• Take the label from the magazine

• Charge electro statically the label, so that it sticks to the mold wall

• Insert label in the mould

• The hot plastic envelopes the label making it an integral part of the moulded item

• Simultaneously remove the finished part and hand over the label

IML- PROCESS CYCLE

Electro statice device

IML- PROCESS CYCLE

WHY IML – SUCCESS STORY

The label becomes an integral part of the product, rather than resting on the outside

The label thereby takes on structural as well as decorative value whilst reducing package weight by as much as 10% to 15% while adding also sidewall strength

Improvement of side wall strength of a container up to 120%

IML improves ‘BRAND IMAGE’ of the product

With a attractive and colorful packaging thesales increase of 30%

Within the packaging, the container itself that ultimately attracts the consumer to the product and makes the sale

IML- Consumer

• Heat transfer labeling cannot quite reach the high level of printing of IML• Heat transfer labels do not provide top-to-bottom coverage• IML's polypropylene labels compare to heat transfer foils and wraps provide a much higher

degree of heat resistance , scratching, pealing, tearing and fading

Top and bottom not cover Nearly 100% of the heigh decorateHeat transfer IML's 'no-label' look

The pail is the same size, people perceive it as a bigger containerIt gives a better shelf presence and a stronger 'billboard effect‘.

Full surface area

decoration with IML

IML Vs Heat Transfer

• The glue applied the label ‘on’ the surface

• With IML the label is ‘in’ the wall of the item, there is a total bond between the label and the plastic. Label cannot be peeled off

• IML labels offer better resistance to moisture, chemical, scratching and surface scuffing because of the material PP compare i.e. to paper

• For injection molded tubs, all four sides and the bottom can be decorated with a single label during the molding process, something that pressure sensitive cannot do.

• Light weight of part, because label displaces synthetic granulate equal to own volume (granulate savings ≠ 10-15%)

IML Vs Self Adhesive Labels

Most of the inks for screen printing are applied with a heavy coverage so the ink layer takes a long time to dry. The printed products must be dried

Decoration in made in several steps (one colour per time)

High costs of storage of blank products and during the steps of decoration

Usually used with few colours to be cost attractive (low image quality)

Low resistance of ink to scratching

Advantage of screen printing / serigraphy : give a soft texture of the printing area creating a tactile surface

IML Vs Silk Screen Printing

• Shrink sleeves are normaly used for bottles

• With specific shape and tamper-evidentband

• Cost of sleeves

• The film shrinks when heat is applied

• The full body shrink sleeve fits theentire body of the container

• The top of the sleeve can be perforatedto form a tamper-evident band.

IML Vs Shrink Sleeve

IML can be applied to all container sides including lids and bases for a maximum graphical impact

Counterfeiting or copying more difficult

Use and re-use containers that are functional enough

Graphic quality that is brilliantly colorful and true-to-life

IML- BENEFITS

Hygienic because decoration is done in one step

Print quality with photographs, 3D images

Easy to change the print by changing labels inside the magazine

High resistance to scratches, humidity, heat, cooling, deep freeze microwaving

Environmentally friendly because 100 % PP, easily recyclable

IML- BENEFITS

All conventional methods of decorating injection moulded products:Pressure-sensitiveGlued-on labels,

Shrink-sleeve labels, Pad and offset printing,

Heat-transfer foils and decalsAll of them involve secondary operations NOT IML

IML- EMERGING CONCEPT

• HIGH PRECISION MOULD

• FAST & ACCURATE ROBOTICS WITH ACCESSORIES

• ULTRA HIGH SPEED INJECTION MOULDING MACHINE

IML- CONSTITUENTS

Expertise and know-how of more than 30 years

2 locations in France

Automation systems for In-Mold Labeling & Moulds

More than 1,500 systems installed worldwide

IML-Technology Center –Wittmann France

W727 CW727 C( Round cup 4 cavities)( Round cup 4 cavities)

W727 L W727 L ( Round lid 2 cavities)( Round lid 2 cavities)

W727 C W727 C ( Round cup 2 cavities)( Round cup 2 cavities)

W727 SM ( Stack mould 4+4)W727 SM ( Stack mould 4+4)

IML robots Side entry

IML- ROBOTICS

W732 ( Rectangular W732 ( Rectangular container 1 cavity)container 1 cavity)

W711 (2 cavities Lid)W711 (2 cavities Lid) W721( Round lid 1 cavity)W721( Round lid 1 cavity)

IML robots Top entry

IML- ROBOTICS

Products and solutions offered to customers:High-performance multi-cavity molds for thin walled containers and exchangeable cavities Expert know-how to realize demanding solutions with the experience of more than 52 yearsStaff is permanently trained both internally and externally to have an update technical expertiseDeveloping strategic partnerships with customers to help to improve the product and to optimize the production

IML- MOULDS

2+2 mould container + lid2+2 mould container + lidFamily productFamily product

2+2 Mould lid hinge Butter product2+2 Mould lid hinge Butter product

Mould 4 cavitiesMould 4 cavitiesRound cupRound cup

Mould 4 cavitiesMould 4 cavitiesSquare containerSquare container

Mould 2 cavitiesMould 2 cavitiesRectangular Rectangular containercontainer

Pate cupsPate cups

Chocolate containersChocolate containers

Ice cream boxesIce cream boxes

IML- MOULDS

The injection press must be specific for the plastic packaging tThe injection press must be specific for the plastic packaging to reach the market demando reach the market demand

• Short cycle time• Huge volume of production• Thin walled moldings• High pressure

The BATTENFELD IMM series TM Xpress is specially designed for packaging

WITTMANN Group offers IML turnkey solutions by integrating systems all round injection moulding machine, automation, mold, process, training and service, with the insurance that individual components are competitive and successful in world markets

IML- MOULDING MACHINE

Faster Processor provides higher

performance

Removable sub-pendant

Storage Device USB

pictures can be linked to a teach

program.

Teachbox R 8 Touch Screen

IML- ROBOTICS - CONTROLLER

Flat on 1 side for lids

3 or 5 sides for containersCross / Butterfly labels

360° wrapped around

IML- LABEL LOCATIONS

IML whole package for 4 or cavities bucketIML whole package for 4 or cavities bucket

IMM 160TIMM 160T

CYCLE TIME = 4.8 sCYCLE TIME = 4.8 s

WALL THICKNESS = WALL THICKNESS = 0.60 mm0.60 mm

Compact design with low maintenance Compact design with low maintenance componentcomponent

Fast cycle time with a good reliability reject part Fast cycle time with a good reliability reject part < 1%< 1%

IML magazine with removal cartridgeIML magazine with removal cartridge

Fill up magazine without stop productionFill up magazine without stop production

Round cup 300 cc – 4 cavity

IML- PROVEN PROJECTS

2 Robots W727

Molding machine size: 160 T

Total cycle time: 3.5sec.

Removal time: 1,3sec.

For molds with 2+2 or 4+4 cavities

For the production of lids and cups at the same time

Cycle time varies according to the machine manufacturesCycle time varies according to the machine manufactures

IML for stack Molds


• Cycle time: 5s• Take out time : 1s• Press: 100T to 500T• Man less operation: 8 hours

FRONT VIEW

LABEL

Butter Tub – 4+4 Stack Mold

Cycle time varies according to the machine Cycle time varies according to the machine manufactures manufactures

FINISHED BOX


3L3L--BucketBucket 5L5L--BucketBucket

Why that choice ? = Top Entry RobotWhy that choice ? = Top Entry Robot

•• Parts position in the mould downward Parts position in the mould downward (mould manufacturing reasons well (mould manufacturing reasons well adapted to the project)adapted to the project)

•• Parts center distance (not possible to Parts center distance (not possible to take out with side entry robot)take out with side entry robot)

•• Cycle time >10 secCycle time >10 sec

•• The most economical The most economical

Robot solution for container


3L 3L --LidLid 5L5L-- LidLid

Why that choice ? = Side Entry RobotWhy that choice ? = Side Entry Robot

•• Cycle time < 7 secCycle time < 7 sec

•• The most economical adapted solution to The most economical adapted solution to the project. the project.

Robot solution LID


Robot W641 (2 Robots with common Z-Axis)

Molding machine size: 900 T

Total cycle time: 40sec.

Removal time: 8sec.

For molds with 1 cavity

Cycle time varies according to the machine manufactures Cycle time varies according to the machine manufactures

Top entry model


Robot W643SS3

Machine size: 480 T

Total cycle time: 30sec.

Removal time: 5sec.

For stack molds 1+1 cavities

EndEnd--ofof--ArmArm ToolingTooling withwith staticstatic chargercharger

Cycle time varies according to the machine manufacturesCycle time varies according to the machine manufactures

IML for Stack Mold


Mold into the appropriated machineOptimal life of the toolQuality of the moldingsReliability of the automation cell

WITTMANN offers a worldwide turnkey solution

IML –TURNKEY SOLTUION

Complete analysis of your project from conceptionChecking the design of the part is suitable for the IML processIntegration of the robot in your plant and optimisation of the process for a turn-key solutionSupply of test labels to start the production

Side Entry robot for low cycle time & high volume of production

IML- CUSTOMIZED STUDY

Successful integration of automation

Side-entry robots fastest response times for IML typically 5 seconds or less

Top Entry robot flexible production

IML –TURNKEY SOLTUION

Wittmann IML Samples

Compatible Automation with all IMM

Name / Datum

Anticipating your proposals !!!

Wittmann Battenfeld India Pvt. Ltd.Chennai.Phone +91 44 442077009Fax + 91 44 23719602E-mail: [email protected]

Technology working for youTechnology working for you

a strong family with a superior features - packplus.in · 2+2 mould container + lid family product...

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