In-Mold Labeling (IML) is Becoming a Reality

IML has been a hot topic for several years as plastics processors try to streamline operations and lower costs. IML is seen as a key new technology in meeting this goal. Traditionally, European companies have led the way in IML, particularly in packaging. North America is fast adopting this technology and Ventax Robot is active in providing both custom and high-speed solutions for their customers.

Ventax Robot Customizes for IML Results

Ventax Robot recently built 2 custom solutions for a major consumer packaging company.

Cell 1 - Adapting to Existing Blow Molding Equipment

The first system made use of an existing blow molding machine. This application was unique in that the machine could not be accessed from the front because of other equipment. The 2-cavity tool had to be loaded from behind and above the cavity position. Available space between the mold halves, when in the open position, was also a concern. The label was a unique shape and needed to be placed on both mold halves (4 labels).

Ventax designed a custom system for this 2-cavity 4-label project, which included a linear robot positioned at the correct angle to clear the press and access the cavities. The End-of-Arm-Tool is designed to interface with two Ventax custom magazines in the horizontal position as seen in the picture. The unique label shape and composition presented several challenges that Ventax was able to deal with through customization of the interface plate and EOAT. The EOAT can load both sides of the mold simultaneously. The entire system, including guarding, is mounted on the back of the blow molding machine and is clear of obstructions.

Key Advantages

• Custom Design - A dedicated linear robot and frame system ensures access and minimized footprint.
   
• Specialized EOAT - Designed to interface with 2 magazines and 4 mold halves with simultaneous motion.
   
• Engineered Magazines - Precision tooling, low quantity signal and convenient loading access ensure reliable accurate label supply to the system.

Cell 2 - The Next Generation of High-Cavitation Blow Molding Machines

The second system was designed to address modern high-cavitation blow molding machines. The challenge was to precisely insert 16 labels into an 8-cavity tool while providing the flexibility to run on any one of 4 machines that the tool may be installed on.

The Ventax solution was to design a custom side entry system featuring an LS 206 SE high-speed robot and servo magazine positioners. The cell as shown in the picture retrieves and loads 16 labels. The LS 206 SE robot has a telescopic linear arm with a 600mm X stroke allowing the robot to first load 8 labels simultaneously on one side and then address the second side to load the remaining 8. A unique servo positioning system for the horizontal magazines allows the robot to retrieve two rows of 4 labels, in sequence, for the left hand dual EOAT's. The right hand EOAT's are then loaded in sequence from the second magazine positioner. This specialized design reduces the need for 16 magazines to only 4. All loading is done while the press is molding parts. In addition, the system features both a permanent and interface frame, with onboard electrical cabinet, allowing the cell to be quickly moved and setup on any other machine that a permanent base frame has been installed on. The cell was specified to run on 4 different blow molding machines.

The LS 206 SE Advantages

• Superior Robotic Solution - The unique linear side entry arm and integrated 600mm strip stroke significantly reduces the footprint of the robot, when compared to articulated robots, and allows for efficient access on high cavity applications.
   
• High-Speed Servo Control - Programmable for speed and position, the LS 206 SE significantly reduces intrusion and cycle times.
   
• Unique Magazine Positioners - 2 servo controlled vertical axes and quick-change magazine interface plates allow for accurate label loading, easy access and significantly reduced magazine cost.
   
• Custom Tooling - Precision Magazines and End-of-Arm-Tooling ensure accurate and repeatable label placement.
   
• Cell Mobility - A heavy-duty interface and base steel frame system combined with onboard electrical make this system the ultimate in providing flexibility and reducing the need for dedicated robot processing cells.
   
• Simple to Use - Ventax's proven high-performance servo control systems feature intuitive operator screens, a user friendly hand held pendant and 25 online programs with instant recall for multiple production requirements.

Ventax Viper Can Handle High-Speed IML

The Issues

Maintain an intrusion time of 1 second or better while addressing the need to place labels and retrieve parts at the same time. In addition, handle the unique requirements of 4 sided container labels.

The Viper AS 206 SE Rises to the Challenge

Ventax addressed this unique combination of customer specifications with a high-speed AS 206 SE robot and custom loading and stacking system as shown in the 3-D image.

The Viper side entry robot is specially designed to allow for dual End-of-Arm-Tooling to address both sides of the mold simultaneously. A custom horizontal magazine system presents the labels for retrieval. The label is then precisely positioned into a forming nest to fold the four flaps over onto the End-of-Arm-Tool. Upon signal, the Viper enters the mold area. The EOAT inserts the labels into the square cavity and simultaneously retrieves the molded parts from the moving platen. The Viper arm exits the molding area and, using its integrated strip stroke, loads the finished parts onto a unique servo transfer arm. The parts are placed on the arm in the vertical position, flipped 90 degrees and stacked using the programmable palletizing program.

Viper AS 206 SE IML Advantages

• Revolutionary Viper 206 SE - The unique synchro-link arm design and integrated strip stroke provide IML intrusion times of 1 second or less and allow for post-mold positioning and retrieval capabilities.
   
• Custom Label Presentation and Forming System - Precision magazines with low label indicators, combined with forming nests, ensure that labels can be placed accurately at high-speed.
   
• Unique Transfer and Stacking Robot - Integrated servo control, combined with a unique EOAT design and built in palletizing program, provide an efficient high-speed stacking solution.
   
• Minimized Footprint - Up to 50% less press side space is required for this system when compared to traditional IML systems.
   
• Easy to Program and Use - Ventax's proven high-performance servo control system runs all primary and secondary equipment. Up to 25 online programs with instant recall are available for multi-part production.
   
• Expandable - Additional packaging equipment such as box staging and loading systems can be added as required.

Check out our product section for more detailed information and specifications on our 
new line of Viper robots.