At the Engel booth of the Fakuma 2014, Beck Automation is
presenting a highly dynamic IML system. The manufacturing cell consists of a
fully electric injection moulding machine Engel e-motion 440/160 and a 2-cavity
injection mould by Glaroform. The feed and removal system for in-mould
labelling is to be considered a reference with regard to speed, footprint,
availability and process security for IML automation. The system is equipped
with an Omron high-grade camera inspection system for quality control of the
containers produced, designed and integrated by Beck Automation.
The IML automation by Beck Automation is designed to be
extremely space-saving and features a small footprint. "This IML system is
compact and yet very easily accessible, meaning user-friendly" explains
Daniel Merki, Sales Manager at Beck. "Thanks to our construction principle
and the various tests we run prior to delivery, we can keep the installation
time on site at our clients very short. We don't just talk about "just in
time", we mean it." As usual at Beck Automation, this involves a high-speed
application (total cycle: 2.9 seconds,intervention time 0.9 seconds). Equipped
with the latest in control and drive technology, the system is operated via a
touch screen. The integrated remote access allows for dialling into the system
from outside, in order to provide support to the user in a timely and
cost-effective manner.
High QA level due to
integrated camera inspection
The quality of the highly dynamic process is assured by a
vision system. The high-grade FZ3 camera system comes from Omron in Japan.
Engineering and integration are coordinated to the specifics of every
application by Beck Automation."The structure and number of camera
inspection modules depend, among other aspects, on the control requirements of
the packaging unit, cycle speed and the number of cavities", explains
Daniel Merki. It is the job of the Omron FZ3 vision system to identify
defective parts. To accomplish this, 1 to n cameras and the necessary
illumination are integrated into the IML automation. The specific number of
cameras needed is defined in detail by various factors:
a) By the product that is to be monitored (shape, size, test
criteria, etc)
b) the quantity of products (number of cavities and cycle
time) as well as
c) place and time of the inspection within the process
The preliminary clarifications and system definitions are
extremely important and have a great impact on the cost structure and options
or capabilities of such a system. Longstanding experience with IML applications
and the specific systems integration by Beck Automation offer IML users a
reliable basis for expert consultation and support for the implementation of a
process-oriented solution. There is an option to expand the system shown by a
QA module (Q-SORT LINE), which can be retrofitted at any time. Daniel Merki
notes, "This separation of good and bad parts, and the subsequent stacking
unit in one highly dynamic system, provides the processor with an even higher
level at which to secure his efforts to achieve high quality and an enhancement
of efficiency in the IML process."
IML technology in the
reference class
As IML is a highly dynamic process, profitability is derived
from the level of all system components. In an initial step the labels are
drawn in from the label hopper. In a second step, the labels are placed on the
cores and held with vacuum. The automated cores move into the cavities to
transfer the labels. In this stage the labels are blown against the vacuum,
electrostatically charged and thus placed and held in the cavities so they are
form-fitting. This makes the level of process design and quality of the label
key factors in process stability, reproducibility, unit quality and economic
efficiency.
Swiss-made thin-wall
technology by Glaroform
Glaroform AG, Näfels (CH) is showing a high speed injection
mould on a fully electric injection moulding machine Engel e-motion 440/160
with 2 cavities for a food container with a round-oval size of 500 ml. The
mould features a proprietary hot runner system with a pneumatically operated
valve gate nozzle. The moulded part is decorated at its side wall by IML. The
mould is equipped with a conformal and high-efficiency cooling system, to
guarantee a very rapid cycle time with simultaneous reproducible product
quality. The conformal cooling also effectively reduces any warping in the
part. In order to also guarantee the very long service life of the moulds for
which Glaroform is well known, the mould is manufactured with the latest
surface coating processes for outstanding process stability and the highest
precision within tight tolerances. The thin-walled product has an average wall
thickness of 0.4 mm and features a part weight of approx. 11 g.
Product Communication
with high-quality labels
The labels used consist of a 60µ EUP orange peel film made
of a material called Treofan by Viappiani Printing Segrate (Italy). The rounded
oval shape of the food container requires labels that are, on one hand, stamped
out with a high degree of precision and on the other hand, ensure observance of
the short cycle time due to a good electrostatic charge. The sheet offset
process guarantees superb printing quality both for four-colour photographic
images and Pantone colours. Viappiani can print IML labels in up to 8 colours,
including varnish coating. This gives users access to a wide range of options
to enhance their product communications at the POS with a visually high-value
appeal and in this way emphasise features that may influence purchase
decisions.
