IML(In Molding Label)

FAQ Guide

In today’s fiercely competitive marketplace, brands are compelled to captivate consumers’ attention. The packaging of a product plays a pivotal role in shaping consumer behavior, as the presentation of a product can profoundly influence its perceived value and allure. In-Mold Labeling (IML) stands out as a groundbreaking process that is revolutionizing product packaging. In this blog post, we will take a mere 5 minutes to explore the captivating realm of IML, delving into its intricate process, the materials involved, and the myriad of advantages it bestows upon products.

1. What is IML?

IML, short for In Mold Label, represents a state-of-the-art injection molding technique that merges labels with molded products. This innovative process enables the creation of vivid, enduring, and seamlessly integrated labels that command attention on the retail shelf.

When employing IML technology, a pre-printed paper label or plastic film label is carefully positioned within the mold. Subsequently, the label undergoes a seamless fusion with the thermoplastic material during the molding process, effectively amalgamating the production and labeling procedures without the necessity for post-labeling. Following the curing process, the container and label coalesce into a singular, waterproof, and scratch-resistant entity.

2. Types of In Mold Label

While In Mold Labeling (IML) offers significant benefits and cost-saving advantages, it is imperative to acquaint yourself with the distinct variations available to select the most fitting option for your project. There exist three primary types: injection, blow, and thermoforming IML. However, comprehending their unique methodologies and specific applications is crucial in determining the most suitable choice for your endeavor.

1) Injection Molding IML

This category is particularly well-suited for large-scale production as it entails infusing molten plastic material subsequent to the insertion of the label into the mold’s cavity. This process yields products with a premium finish sans the necessity for post-labeling. Its key strength lies in its exceptional precision, making it ideal for labeling intricate structures in substantial quantities.

2) Blow Molding IML

The distinctive utility of blow mold IML lies in labeling plastic containers and bottles, where air is utilized to shape the mold. The initial step involves placing the labels within the blow molds, followed by the introduction of air to mold the product into a cohesive entity with the label seamlessly integrated. Careful placement of the labels within the blow molds is essential to safeguard them against abrasions and scratches during production.

3) Thermoforming IML

Since the labels must be placed in the thermoforming mold before the plastic product is formed, a thermoforming mold is essential to this in-mold labeling method. In manufacturers of small-thickness plastic lids, covers, and trays, this type of IML is applicable. Its main strength is its versatility, allowing labels to be made from a wide variety of materials.

In addition to their unique advantages, IML types are suitable for a wide range of applications, including complex shapes and designs. To select the right IML type, considerations such as material type, shape, and design must be taken into account. Making the right choice is easier if you consult with seasoned IML manufacturers.

3. Materials and Substrates of IML

The selection of appropriate materials for in-mold labeling is a critical aspect to consider, as not all materials are conducive to this process. Opting for the right material that aligns with the in-mold labeling type for your project is paramount.

In mold labeling endeavors, materials boasting exceptional molding characteristics are highly sought after. Polypropylene emerges as a prominent choice for IML applications owing to its robustness, thermal attributes, and versatility. Additionally, polyester and polyethylene are favored materials renowned for their durability, flexibility, and printability. These three materials are well-suited for molding projects necessitating elevated temperatures and pressures, as they exhibit remarkable resilience in extreme thermal conditions.

Nevertheless, the compatibility of label materials with diverse plastic substrates is a pivotal consideration in IML processes, given that certain materials may not harmonize well with plastics. For instance, employing PP labels with compatible plastic materials such as polyethylene and polypropylene, both of which belong to the polyolefin family, is advisable.

Conversely, these materials may not be suitable for crystalline plastics like PET, nylon, and polycarbonate. It is customary to conduct compatibility assessments to verify the adhesion of labels to plastic substrates, thereby mitigating issues such as warping and other irregularities. In instances where popular label materials may not be suitable, alternative substrate materials possessing requisite properties such as flexibility, reflective qualities, and strength can be utilized.

These substrates may encompass paper, metals, or even cardboard. However, specific surface treatments may be necessary to facilitate proper bonding between these substrates and the plastic material.

Ultimately, the selection of appropriate label materials hinges on the choice of plastic material designated for the product. Moreover, a meticulous evaluation of compatibility concerns will ensure a superior finish characterized by exceptional durability in your in-mold labeling application.

4. How does IML Work?

The intricacies of the in-mold labeling (IML) process unveil a realm of possibilities for product enhancement. Among the myriad techniques employed, three standout methods—namely injection molding, blow molding, and thermoforming—hold sway in the realm of IML. While each technique boasts its unique merits, it is the labeling process that sets them apart.

1) In Mold Labeling Injection Molding

Injection molding stands as the cornerstone of the in-mold labeling process, revered for its prevalence and efficacy. Beneath the seemingly straightforward facade of injection molding lies a tapestry of variables that demand meticulous control to ensure the impeccable quality of the resultant plastic components. A profound comprehension of the process and its parameters empowers manufacturers to source plastic component suppliers capable of delivering the desired quality and consistency.

The sequence of events in in-mold labeling injection molding unfolds as follows:

(1) Selection of Appropriate Thermoplastic and Mold

Prior to commencing the process, the judicious selection or creation of suitable thermoplastics and molds is imperative, as these elements serve as the very essence of manufacturing and shaping the final components. The interplay between thermoplastics and molds necessitates careful consideration to make informed choices, given that certain plastic types may not align harmoniously with specific mold designs.

(2) Thermoplastic Feeding and Melting

Injection molding equipment may be powered by either electricity or hydraulics. The initiation of the process sees raw thermoplastic pellets introduced into the machine’s hopper. As the screw rotates, these pellets are gradually fed into the machine’s barrel. Through the combined action of screw rotation and barrel heat, the thermoplastic undergoes a gradual process of heating and melting until it attains a molten state.

(3) Plastic Injection into the Mold

Upon reaching the end of the barrel, the molten plastic triggers the closure of the gate, prompting the screw to advance. This action draws a predetermined volume of plastic through, creating pressure within to prepare for injection. Simultaneously, an available label is positioned inside the mold. The two components of the mold tool are firmly secured together under substantial pressure or clamp pressure.

Fine-tuning of injection pressure and clamp pressure is essential to ensure proper component development and prevent plastic leakage during injection. Once the requisite pressure levels are achieved in the tool and screw, the gate opens, the screw advances and the molten plastic is injected into the mold.

(4) Holding and Cooling Phases

Injection of most of the plastic into the mold is followed by pressure applied for a certain period of time. It may last anywhere from a few milliseconds to several minutes, depending on the type of thermoplastic and the complexity of the component. This holding period is crucial for ensuring that the plastic forms properly and packs out the tool. When cooled, it conforms to the mold and bonds with the label.

(5) Finishing and Ejection Procedures

Upon completion of the holding and cooling stages, pins or plates expel the components from the mold, ushering them towards the machine’s base where they are directed onto a conveyor belt or into a receptacle. The end result is a meticulously crafted plastic product adorned with a seamlessly integrated label.

The culmination of the molding cycle signifies the completion of plastic mold labeling, obviating the need for post-labeling and ancillary operations. The in-mold labeling injection molding technique stands as a beacon of efficiency, finding widespread application in the production of computer keyboards, mobile phone keypads, and compact plastic paint buckets.

2) In Mold Labeling Through Blow Molding

Among the pantheon of techniques for in-mold labeling, blow molding emerges as a prominent contender. Within this process, the raw plastic material undergoes a metamorphosis into a parison—a hollow tube with one aperture. Analogous to in-mold injection, the decorative label finds its abode within the cavity wall of the mold, intertwining with the molded plastic as it cools within the mold cavity.

The realm of blow molding unfolds through three distinct processes:

(1) Injection Blow Molding

A blow or core rod is utilized throughout the injection blow molding process. A parison is first poured into the split mold cavity around the rod. The resulting parison has a test-tube-like appearance. Through the core rod, the parison is fed into the blow mold machine, where compressed air produces the final form. Afterward, the final product is transferred to the rod, which extrudes it.

(2) Extrusion Blow Molding

Within the tapestry of extrusion blow molding, two variations—continuous and intermittent—beckon. In continuous extrusion blow molding, each form sprouting from a perpetually supplied parison is deftly severed with a blade. Conversely, intermittent extrusion blow molding orchestrates the extrusion of fresh plastic from the metal mold after the antecedent plastic has been evicted, cooled, and nestled within the mold.

The allure of extrusion blow molds lies in their swifter creation and lower cost relative to injection blow molds, rendering them ideal for smaller production runs. While the benefits encompass diminished tooling expenses and expedited production cycles, the drawbacks often manifest as diminished control over wall thickness and heightened material wastage.

(3) Injection Stretch Blow Molding

A harmonious fusion of injection molding and blow molding characterizes the ballet of injection stretch blow molding. The plastic undergoes an initial transformation into a solid preform, culminating in the creation of a threaded bottleneck. Subsequently, a stretch blow mold machine cradles the preform post-cooling. Infused with compressed air, the plastic bottle undergoes a metamorphosis, while the preform basks in the radiance of an infrared heater.

This method predominantly begets hollow plastic artifacts, reminiscent of erstwhile glass bottle production. Presently, plastic bottles stand as the quintessence of this technique’s prowess, serving as vessels for an array of liquids—from shampoo and dishwashing detergent to ketchup and sauces.

3) In Mold Labeling Through Thermoforming

Thermoforming, an intricate process, entails the meticulous heating of a thermoplastic sheet until it reaches a state of malleability. Once draped over a mold with singular grace, the sheet undergoes a subtle metamorphosis as it conforms to the mold’s contours, solidifying into its final form as it gracefully cools. Within the realm of thermoforming, three distinguished techniques—vacuum forming, pressure forming, and mechanical forming—stand as pillars, shaping the sheet into its destined embodiment.

This artistry of thermoforming transcends boundaries, offering a plethora of applications across diverse industries.

(1) Shaping

Through the deft touch of a shaping implement, heated plastic sheets are sculpted into precise forms. Unlike the all-encompassing heat of injection and blow molding, the plastic sheets are delicately warmed around the shaping tool. Post-cooling and solidification, the once pliable sheets assume the contours of the formative mold, embodying a new identity.

(2) Heating

Before the heated plastic sheets envelop the forming tool in a dance of transformation, a printed label finds its place within the mold. The molten plastic sheets, as they cool and solidify within the mold, embrace the printed label, birthing a plastic creation bedecked in its entirety.

The tapestry of thermoformed creations predominantly comprises rigid plastic packaging, essential in the crafting of plastic vessels like cups. This method finds resonance in the creation of containers for delicacies such as ice cream and coffee.

Plastic tubs, guardians of frozen delights, also owe their existence to thermoforming artistry. Beyond packaging, thermoforming weaves its magic into the creation of an array of products—from blisters and trays to lids—serving industries as diverse as culinary, medical, and retail.

Thermoforming stands as a testament to the fusion of art and science, breathing life into a myriad of creations that grace our daily lives with elegance and functionality.

5. Advantages of In Mold Label

The realm of In-Mold Labeling (IML) technology unfolds a tapestry of advantages that have elevated it to a position of indispensability across diverse industries. Here, we delve into the exquisite advantages of this technology:

1) Diverse Decorative Possibilities

IML technology offers a symphony of decorating options, characterized by swift design transitions and the utilization of multi-color and lithography printing techniques. This results in the creation of products boasting superior quality that resists abrasion, ensuring longevity and aesthetic appeal.

2) Aesthetic Enhancement

IML technology transcends mere decoration, elevating the appearance of products to unparalleled heights. With captivating designs and visually striking imagery, products adorned with IML effortlessly captivate the gaze of potential customers. The integration of product information within the labels further enhances the allure, while the seamless fusion of label and product enhances structural integrity. The permanence of this fusion ensures that the label remains unblemished throughout the product’s lifecycle.

3) Enhanced Production Efficiency

IML technology heralds a new era of production efficiency, characterized by reduced production times and lower costs. By enabling the simultaneous production and decoration of containers, the need for storing blank containers is obviated, thereby eliminating storage and transportation expenses.

4) Counterfeit Prevention

The intricate nature of IML necessitates the use of bespoke molds, crafted with precision and requiring substantial capital investment. The complexity and cost involved in mold production act as formidable barriers against counterfeit practices. The unique mold designs, coupled with the intricacies of film printing and label formation, render replication nearly impossible. This fortification serves to safeguard brands against the perils of counterfeit products, preserving brand integrity and authenticity.

6. Disadvantages of In Mold Label

The utilization of sophisticated tooling and robotic systems in in-mold labeling comes at a considerable cost, thereby amplifying the overall production expenses associated with this technique.

Furthermore, the temporal demands of in-mold labeling pose a significant hurdle. Lengthy production runs are necessitated, as shorter runs prove exorbitant and entail extended setup times, contributing to operational inefficiencies.

The economic viability of in-mold labeling is further compromised by the frequent tooling modifications required throughout the labeling process, leading to disruptions and increased costs.

Moreover, a notable concern lies in the elevated product defect rate associated with this method. The defect rate serves as a critical metric, reflecting the proportion of flawed components amidst the total production output. A surge in the defect rate signifies substandard manufacturing practices, resulting in deviations from the intended design and compromising product quality.

7. Applications of IML

The versatile nature of In-Mold Labeling (IML) technology has heralded a new era of innovation across a myriad of industries, with label manufacturers in India spearheading the adoption of this packaging marvel. Here, we illuminate the profound impact of In-Mold Labeling in key sectors:

1) Automotive Sector

Within the realm of automotive excellence, IML technology shines brightly, particularly in the realm of car interiors. Here, it enables the creation of robust control panel labels, interior trim components, and distinctive branding elements. The resilience of IML against the ravages of time elevates the durability and aesthetic allure of vehicles to unparalleled heights.

2) Consumer Electronics

In Molding labels are widely adopted in the consumer electronics sector for their durability. As a result, remote controls, mobile phones, and home appliances have a sleek, seamless appearance.

3) Medical Devices

IML stands as a beacon of precision and reliability. Vital for accurate labeling in the medical sphere, IML technology’s resistance to harsh sterilization processes and chemical exposure ensures the longevity and legibility of labels on essential medical equipment and devices.

4) Toy Manufacturing

The enchanting world of toy manufacturing finds solace in the protective embrace of IML technology. Vibrant and child-friendly labels, crafted with IML, withstand the rigors of playtime and stringent safety standards, safeguarding toy branding integrity and ensuring the safety of young ones at play.

8. Conclusion

In conclusion, the advent of In-Mold Labeling (IML) has indeed revolutionized the packaging realm, showcasing its versatility and myriad benefits across diverse applications. This innovative technique has not only proven its utility across multiple sectors but has also conferred a competitive edge to those who embrace it in the market landscape.

With the escalating demand for visually captivating labeling solutions, manufacturers specializing in In-Mold Labeling stand poised to cater to the ever-evolving needs of various industries, ensuring a seamless convergence of aesthetics and functionality in the realm of packaging.