In-Mold Labeling Technology and Trends presentation by StackTeck Inc. at the AMI Thinwall Packaging 2015 Conference, entitled: "Advanced IML Systems Technology to Minimize Cost"

1. Advanced IML Systems Technology to Minimize Cost
AMI Thinwall Packaging 2015
Jordan Robertson
Focused Expertise. Benchmark Performance.Focused Expertise. Benchmark Performance.

2.  High cavitation solutions to minimize IML part cost
 Ultra-Thin TRIM molding technology
 Future developments
Agenda

3. Conventional Stack Mold

4. IML Robot for Stack Mold

5. Simplified IML Container Stack Mold Layout

6. 2x16 Layout

7. Robot Drawing for 2x16 Cup Mold

8. Hot Runner Layout: 2x16 IML Cup Mold

9. IML Stack Mold for Container

10. Dual Compartment Containers

11. Dual Compartment Container Mold

12.  4 horizontal rows of mandrels/magazines
 Mold pitch if driven by magazine size
 Complexity of collapsing mandrel pitch
 Manual adjustment of magazine positions
 Stack molds usually simplify any cavitation
 2x8 simpler than 1x16
 2x16 simpler than 1x32
Challenges with ≥ 16 Cavities per Face

13. Perceptions:
 Stack molds limit options
 Limitations of number of labels
 Limitation of system cavitation
 High cavitation >= 16 is complex and involves risk
High Cavitation IML Systems

14. Perceptions versus reality:
 Stack molds limit options
 No limitations with custom hot runners
 40% of IML cavities go into stack molds
 Limitations of number of labels
 24 & 32 label systems run well
 Limitation of system cavitation
 Over 50 IML stack molds built
 High cavitation >= 16 is complex and involves risk
 Over 25 molds running well with 16+ labels
High Cavitation IML Systems

15. Advantage of Stack Molds & High Cavitation*
System Information Low High
Number of Systems 12 1
System Configuration 1x2 2x16
Cycle Time 4.6 sec. 5.8 sec.
Equipment Cost $ 2,612,400 $ 1,361,000
Hourly Output (pph) 18,782 19,862
Annual Output (ppy) 135 M 143 M
(7200 hours per year)
Output over 5 years 676 M 715 M
Capital/Output 0.39 ¢ 0.19 ¢
($ per part over 5 year)
Difference (%) 51 %
* Note: All data from 2004 StackTeck conference presentation.

16. TRIMTM (Thin Recess Injection Molding)
Technology Review:
 Thin panels cover 50-90% of part area
 Ultra-Thin beyond conventional designs
 L/T well over 300
 20%-40% weight reduction
 Aesthetic effect of 90% coverage
Background: TRIM Ultra-Lightweighting

17.  Lightweighting for thinnest, lightest
possible part
 “L” is length of flow
 “T” is average thickness
 “L/T” is abstract measure
 PP food tubs typically have:
L/T = 260-300
Thinwall Packaging
Defining Terms
“L”

18. TRIM - Original Design with 50% Ultra-Thin Panels

19. 2009 In Mould Decorating Award Winner
Awards presented to Sri Thai Superware and StackTeck

20. TRIM Ultra-Thin Part Design
•
•
• B
•
A
• B
A
• B
A

21. TRIM Ultra-Thin Part Design
 First Commercial Application of TRIM
 IMDA 2014 Award “Best Thinwall Packaging”

22. 32 Oz. Container with 90% Ultra-Thinwall

23. 32 Oz. Container with 90% Ultra-Thinwall

24. 32 Oz. Container with 90% Ultra-Thinwall

25. 32 Oz. Container with 50-90% Ultra-Thinwall

26. 32 Oz. Container with 90% Ultra-Thinwall

27. 90% Ultra-Thinwall TRIM Shown at NPE 2015

28. 90% Ultra-Thinwall TRIM Shown at NPE 2015

29. 90% Ultra-Thinwall TRIM Shown at NPE 2015

30. Conclusions
 High cavitation IML systems are proven technology
 Stack molds simplify IML robotics, many such systems running
 Large number of IML systems running with 16+ labels
 Flexible hot runner technology enables more system options
 Lightweighting 40% is feasible vs. conventional
 Unprecedented ultra-thin walls are possible with TRIM
Ultra-Thinwall IML candidates….
 Single serve cups (esp. yoghurt)
 Horticultural
 Hand filled packaging (deli, drive-through)
 Lightweight high volume food packaging
 Functional features (e.g. tamper evident tabs, bale lugs)

31. Thank You
Contact us:
Phone: 1-888-700-8555
Website: www.stackteck.com
© Copyright 2015 StackTeck Systems Ltd.
Focused Expertise. Benchmark Performance.