IML innovations for high impact packaging

Today’s packaging requirements have become more demanding – not only spanning the need to meet stringent health and safety regulations but also responding to the quest for eye-catching and on-shelf appeal. The latter criterion has driven producers of IML equipment and services to strive hard to develop new technologies and processes confirming to current trends.

RPC Bebo Plastik has extended its pioneering In-Mold Label Thermoforming (IML-T) technology and developed a concept that includes the production of lids with enhanced quality decoration.  Using conventional lid forming machinery and with the ability for existing lid tools to be modified for IML-T manufacture, the introduction of the new technology provides food manufacturers with a cost-effective means of creating high impact packaging for premium branding and on-shelf appeal in competitive markets.

RPC Bebo Plastik first introduced IML-T tubs in 2014, bringing additional quality decoration opportunities to the thermoforming sector. IML-T applies pre-printed labels to a container during the thermoforming process, meaning intricate, multi-colored designs in up to eight colors can be incorporated to achieve a better level of finish and greater coverage than with direct printing. In addition, IML-T for lids allows a more precise label positioning than conventional off-mold labeling, and different lid weights can be produced from the same tooling.

The extension of this technology to lids now delivers a complete pack solution, with lightweight containers, high output lines and competitive tool costs offering an excellent return on investment.  “This is a natural development that reflects the success of our IML-T technology,” according to Robert Steinmeijer, RPC Bebo’s sales and marketing manager. “Customers can create effective product differentiation and brand enhancement across our range of convenient, consumer-friendly food packs.”

Typical applications for IML-T packs have included spreadable products, salads and snacks, including a number of replacement projects for cans and glass.

RPC Bebo Plastik’s IML-T technology was recognized in the European Thermoforming Parts Competition 2016. The company’s IML-T tubs and lids took first prize in the category “Thin Gauge – Food Packaging Applications”.  Among the many benefits highlighted by the judges were the wide label coverage that can be achieved including the stacking rim of the pack and the option of barrier protection through the use of multilayer sheet, all of which can be delivered using existing tools.


 

Attractive decoration
A healthy ice cream made from camel’s milk is being sold in RingLock tubs from RPC Superfos that help to convey the qualities of this unique product. Camelait ice cream offers a series of six different flavors launched by Al Ain Dairy Company in the United Arab Emirates.   The convenient, easy-to-use injection molded polypropylene RingLock tub features high-impact golden decoration and a perfect visualization of the ice cream, using advanced in-mold labeling to deliver photos and graphics of a very high resolution that reflect the premium nature of the product.  
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The camel milk ice cream is available in two sizes: 125 ml and 1 liter. For immediate indulgence and eating on the go, the smaller tubs have a practical plastic spoon in the lid.

On the filling line, the packaging solution also lives up to the requirements of Al Ain Dairy Company. The tubs are easy to handle all the way through the filling torque, the hardening tunnel and into the cartons. The RingLock tubs resist blast freezing at temperatures of -25°C. They are 100 per cent liquid tight and come with tamper evidence.


Metallic IML shines bright
On its 50th anniversary, Cofabrill shines brightly with a special anniversary pack in glittering gold. The French producer of professional paint, Zolpan, popped its popular paint pail into a brand new Metallic IML pack. Injection molder RPC Superfos came to Verstraete IML for some shimmering Metallic IML labels. These were the just the ticket to get one of the company’s most popular products all dressed up to celebrate Zolpan’s 50th birthday.

Zolpan belongs to the Cromology Group: a large world player in decorative paint products, operating throughout the world in over 50 countries. Their indoor paint, Cofabrill, has been a favorite among French painters since 1966. This qualitative, water-based satin paint is easy to apply, provides great coverage and has a beautiful glossy texture. In order to celebrate its golden anniversary in style Zolpan launched a special and limited edition onto the market.

Zolpan created a stunning new design featuring a background of golden waves. When this offset decoration was tested on a bucket however, the results were disappointing. That’s why RPC Superfos proposed a Metallic IML label. The pantone colors were replaced by metallic colors, making it highly visible. When the IML pack is used the bucket of paint sparkles as though it were made of real gold. The IML technique ensures that  Zolpan can keep its original paint bucket. By using Metallic IML, a magnificent metalized effect was achieved so that Zolpan can re-use their authentic colors. The characteristics of the bucket, like the seal and the resistance against pressure, are preserved. Moreover, their logistic flow remains unaltered.

Integrating packaging and labeling
Kiri and La Vache Qui Rit, two famous cheese spread brands of the Bel Group, achieved a brand new look via IML technology.  The BEL Group switched from thermoformed packaging with self-adhesive labels to IML packaging: packaging and labeling are now integrated into one whole. The shape of the packaging is unique in the cheese spread market in various ways. The packaging has rounded corners and an asymmetrical shape that has never been seen before. The various sizes ensure that everyone finds what they want within the product range: large and small families and consumers from various countries. The five sizes are: 200 g, 300 g, 350 g, 500 g and 700 g.

The changeover has been a great success, since the BEL Group witnessed a jump in market share for the Kiri and La Vache Qui Rit cheese spread brands in terms of sales volumes and the number of outlets. This testifies to the huge difference that the new IML cheese spread packaging makes on shop shelves. The unique shape and the superior print quality of the IML labels are eye-catching and they focus on the high quality of the cheese spreads.

IML is much more flexible than other decorative techniques and the format of the label can be easily adjusted. It also allows for quick change of artwork during the production process. The BEL Group also limited the number of colors per design to enable the combination of various designs during the printing process.  The process eliminates the costs of storage, transport and (post-production) labeling.  An added plus? IML is environmentally friendly: both the packaging as well as the label are of 100% recyclable polypropylene.