Are you tired of labels that drag or remove? Moreover, they cheap tubs and bottles and smash extra waste. Fortunately, there’s a smarter solution. In-Mold Labeling (IML) solves the problem. Therefore, it fuses the label right into the plastic, keeping it clean and tough for the life of the product.
Forget glue and remove labels. Now, think smart, efficient, and clean. That’s the magic of In-Mold Labeling. In this blog you will learn how IMl technology works and what makes it revolutionary in packaging. So keep reading!
Figure 1: In Mold Labeling
1)What is IML technology
IML stands for In-Mold Labeling. This is a technique for combining a label into a plastic product during its manufacturing process. Therefore, Pre-printed labels are placed within a mold, which is then filled with molten plastic. Well, the sticky part and the plastic are bonded firmly enough that it can not be removed.
Figure 2: In Mold Technology
IML produces shiny and bright images. Moreover, these labels and products, like buckets, tubs, and containers, are made up of the same material (polypropylene). Therefore, IML’s products can be easily recycled; there is no need to remove any paper or glue.
Today, you can also see this technology used in the snack and dairy tubs, spread containers, as well as in the shampoo and soap bottles.
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History of IML Technology
IML started in Europe in the early 1970s. At that time, labels were applied after the container was already made. Therefore, this often led to labels coming loose and producing waste. To solve the problem, packaging engineers came up with a fresh approach.
Firms such as Owens-Illinois and Procter & Gamble lent their expertise to the effort. So, they started putting a printed label directly into the mold. Moreover, when the plastic was injected, it bonded with the label.
Therefore, this made the containers not only nice but also strong. Now, in-mold labeling is the best choice around the globe. As it takes less time, decreases waste, and creates strong, and attractive packaging. All of this is done by using specialized injection-molding machines.
2) How IML Works
Let’s examine the IML process step by step. Each stage shows how the label and plastic merge into a single unit.
Figure 3: IML working
Step 1: Design and print the Label
- Label Design: Firstly, a graphic designer makes a draft of the label design. Also, this includes the logos, texts, images, barcodes, and safety information.
- Printing the Label: Then, the design is printed on a thin IML film ( polypropylene) with special printing techniques such as offset, flexo, or gravure.
- Label Finishing: After that, the film is printed and then cut into the correct shape. Therefore, it is treated to prevent static so that it remains fixed in the mold.
- Ready to Use: At this stage, the label is colorful, flat, and suitably sized for the cup, bottle, or box. Moreover, it features a glue layer that solidifies later to bond the plastic portion. Once it is prepared, it moves on to the next stage.
Step 2: Place the Label in the Mold
Next, the label goes inside a hollow mold of the final product’s shape. Then, machines use a vacuum or static charge to hold the label in place. As a result, it keeps the label secure and prevents movement.
Moreover, when you place a label on a warm plastic surface, the hot plastic comes into contact with the label from all edges. Therefore, the label and plastic bond permanently in a smooth manner.
Step 3: Fill the Mold with Plastic
After that, small plastic beads are transformed into a hot liquid form. This liquid plastic goes into the mold. Then, the label comes into contact with the heated plastic. The high temperature melts the adhesive layer. This fuses the label and plastic into one solid piece.
In this stage, various methods can form plastic into shape:
- For injection molding, firstly, plastic in molten form is injected under high pressure.
- For blow molding: Then, soft plastic is inflated with air to adhere and shape to the mold and the label.
- For thermoforming: Finally, a plastic sheet and the label are heated together to shape them within the mold.
Once the plastic has completely filled the mold, it needs to cool.
Step 4: Cool and Release
As a final step, the mold remains sealed during the cooling process. In this way, its shape becomes hard and strong. Therefore, the cooling phase secures the label permanently. It is guaranteed not to peel off or lose color.
After that, the mold opened. Then, the new packaging is taken out. As a result, the label is attached smoothly. Moreover, it is shiny, energetic, and combined into the packaging instead of being placed on top.
3) Key Benefits of IML Technology
Now, let’s see how IML benefits us. Each of these advantages will show how it improves packaging for you as well as for the manufacturers.
Figure 4: benefits of IML technology
+ Better Look: Firstly, IML produces bright and full-sided prints with folded edges and gives shiny areas too. Thus, products appear fresh and unique.
+ Long-Lasting: Secondly, IML protects labels from scratches, water, heat, during exposure to sunlight. As a result, your package remains fresh for a long period of time.
+ Faster Production: Next, IML applies the label to an item during production. Therefore, there’s no need to apply it later, which saves time.
+ Easy Recycling: Also, both the label and the container are made from the same plastic in IML. This means users can recycle it without having to separate anything.
+ Cost Saving: Last but not least, IML saves on materials and effort in the production of excess items. Therefore, companies that place bulk orders will incur lower costs.
Ashok Kumar Parthipan described the in-mold labeling process. It begins with a lightweight printed film. The ink on this film is composed to bond when exposed to heat.
After that, they set the film into a hard mold. Therefore, compressed air then extends it smoothly against the shape. Once it’s uniformly tight, they dipped in the melted plastic. Then, the heat fuses the new plastic to the film, forming a single, solid piece.
This method lets you apply the design directly onto the box or the tub. Moreover, it also fits nicely on round surfaces. Because you can print and produce at the same moment, you cut down on the time you normally spend moving pieces around.
Plus, there’s no extra label to toss, which makes recycling even simpler. The print is clear and vivid, too, so everything looks great on the shelf. Finally, the material works well for paint cans, ice cream pints, snack containers, and shampoo bottles.
Figure 5: Quora review
4) Technical & Design Considerations
It is helpful to understand what makes IML work well. Here we will discuss a few steps to remember in the designing and manufacturing processes of IML products.
i) Material Compatibility:
First, it’s important to match the label film and the plastic resin. For example, both should reach a melting point at the same temperature. This ensures proper adhesion without separation.
2) Mold Tooling:
Next, the form needs to have small channels for vacuum or static hold. This helps to keep the label secured in the correct position. In addition, some other equipment is used to position the label where it is supposed to be.
3) Surface Finishes:
After that, you can select the appearance of the surface. For example, it may be flat, smooth, rough, or shiny as a piece of metal. Sometimes, some extra layers make it smooth and very shiny. With these techniques, everything has a unique appeal and is interesting to look at.
5) Applications & Industry Examples
There are several applications of IML. Here we will discuss the basic application of IML.
Figure 7: IML applications
- First, IML technology is widely used for packaging ice cream, yogurt, butter, and snacks. You can find this on snack containers and butter tubs.
- Next, IML is used for packaging shampoos, soaps, and perfumes. It encompasses a wide range of personal care items, also.
- In addition, IML is suitable for cleaning supplies. For instance, the method is used for food storage containers, cleaning tubs, and even for detergent bottles.
- Also, some industrial parts employ IML. These include trim panels of cars, internal components of vehicles, and electronic cases.
Conclusion
In-Mold Labeling is a fast process for applying labels to plastic products. The process also accelerates production and lowers the cutting cycle. Because of these benefits, manufacturers across a range of industries prefer IML for its reliability and speed.
At Honokage, we apply in-mould labelling to create packaging that’s both attractive and tough. Plus, it spaces right into the recycling stream without a pull. Get in touch with us, and we’ll guide you to the right IML design for your product.
