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█ K 2013: IML Technology For Food And Non-Food Applications
IML Experts Give New Impulses at K 2013
IML Competence in the Reference Class: "Make It
Simple, fast, and Proven“
The IML Competence collaboration of IML experts involving Beck Automation AG,
Ernst H. Furrer AG, Glaroform AG, Viappiani Printing and BFA Solutions Ltd.
demonstrates the possibilities of a high-performance system for IML technology
(In-Mold Labeling) at K 2013. Visitors benefit from the full expertise that this
collaboration brings to the table, from the injection mold and automation to
labeling through to the final product. IML Competence stands for the high quality
and exacting standards we have come to expect. K 2013 will see new impulses on
simplified operation, QA measures, and documentation options for IML in food
and non-food applications.
The presentation showcases the entire IML range as a reference manufacturing cell.
The long-standing IML Competence partnership permits high availability and top class
performance for manufacturers while being easy to operate and offers new QA
measures and documentation on how to improve the added value of new systems.
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IML Technology to Order: Every Component Counts
As IML is a highly dynamic process, profitability is derived from the level of system
components. Electrostatic charging and core alignment are the key processing points in
the procedure. First the labels are sucked from the label magazine. In the second, the
labels are placed on the cores and held with vacuum. The automation 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
safety, reproducibility, product quality and economic efficiency.
„Swiss-Made” Mold Technology for Thin-Wall Technology
Glaroform AG in Näfels, Switzerland, shows a fast running injection mold with 2 cavities
for a round-oval 500 ml food container. The mold has an on-site hot runner system with
pneumatically operated needle valves. The molded part is decorated with IML on the
sides. The mold is equipped with a form-fitting and highly efficient cooling system, in
order to guarantee a very fast cycle time with reproducible product quality. Form-fitting
cooling also effectively reduces warping of the part. The mold satisfies the latest
standards in design engineering, and is made from pure quality tool steel. To ensure the
long period of application for molds for which Glaroform is renowned, the mold is
manufactured using the latest surface coating processes for excellent process safety,
and with the utmost precision in tight tolerances. The thin-walled product has an
average wall-thickness of 0.4 mm and a weight per unit of approx. 11 g.
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Highly Effective and Easy To Use: Automation with QA Module
Beck Automation AG in Oberengstringen, Switzerland, adds a highly dynamic
automated IML system to the manufacturing cell. The modular cell raises the bar in
speed, availability and process reliability in IML automation. The application cycle time is
less than 3.0 seconds. Beck's system is equipped with the latest in control and drive
technology. It is operated by touch screen. An integrated remote access provides the
option to log into the system from outside in order to provide cost-efficient and fast
customer assistance when required. With this approach, Beck Automation has taken its
systems' user-friendliness to a new level. A camera inspection system from Omron is
used for quality control of the manufactured containers. Any parts determined to be
flawed are rejected by the Q-SORT LINE after inspection, and collected in a NOK parts
box. The good products are then stacked and removed from the system via a conveyor
belt. The Q-SORT LINE can be retrofitted: Existing plants can be upgraded with this QA
module. This separation of OK/NOK units in a highly dynamic system provides a
manufacturer with a completely new level of assistance to ensure that quality assurance
standards are satisfied.
Energy-Efficient Cooling Concepts
The renowned company Ernst H. Furrer AG in Dällikon, Switzerland, supports the
application with temperate cooling water using the newest cooler technology. So-called
"free cooling" can be deployed optionally. This means that cooling is achieved with cold
outside air, as long as the difference is sufficient to permit the desired medium
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temperature. The use of compressors is unnecessary in this phase, enabling power cost
savings of up to 60%.
Accentuate Product Communication with High-Quality Labels
Viappiani Printing in Segrate, Italy, produces labels for this exhibit based on a 60µ EUP
orange peel film made by Treofan. The container's round-oval shape requires labels to
be stamped with the utmost precision and that can guarantee the fast cycle time with a
good electrostatic charge. The sheet offset method guarantees the best print quality for
both the 4-color photographs and the Pantone colors. Viappiani can print IML labels with
up to 8 colors including lacquer coating. This gives users a broad range of options to
lend their products an upmarket look and feel and accentuate them at the point of sale.
Spotlight Shines on Complete Documentation in IML
BFA Solutions Ltd. for the first time ever presents the production data capture for a
closed cell (MDE) in packaging for IML Competence. The product information system
PiSolutions jointly captures, displays and chronologically logs the process data, data
sets, orders, error messages and status information of the exhibited application. This is
a forward-looking step toward Industry 4.0 and complete data recording of a variety of
components with different controllers. In the case of the exhibited application, the
injection molding machine data is recorded by the machine's standardized Euromap63
interface and combined with the automation data received from an OPC interface. This
data is then stored and visualized in a central database. This is made possible by the
newly created combination of the bundled solutions Pi_Inject and Pi_Assembly, each of
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which include the industry-specific features of MES PiSolutions, thereby ensuring a swift
and smooth transition from injection molding and automation. This type of data capturing
supersedes the installation of several independent BDE/MDE systems within a
production environment and can be used as a single, central module which can be
linked to a master ERP system.
Publication free of charge – specimen copy requested
Captions
█████████████████████████████████████████
CAP 0 (lead picture): Thin-wall technology molding for IML: Dual-cavity high-performance mold
by Glaroform
CAP 1: Q-SORT LINE OK/NOK product sorting, stands for quality: Camera inspection Omron /
integrated by Beck Automation
CAP 2: Image/diagram bfa solutions
CAP 3: High-end look at the point of sale: Labels by Viappiani
CAP 4: Energy-efficient cooling concepts by ef cooling: "Free cooling" using cold outside air
saves up to 60% in energy costs
CAP 5: High-performance IML manufacturing cell IML Competence at K 2013
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Beck Automation at K 2013: Hall 10 G77
███████
Contacts
█████████████████████████████████████████████████
Beck Automation AG
Neugutstrasse 19
CH - 8102 Oberengstringen
Schweiz | Switzerland | Suisse
Phone: +41 (0) 44 751 84 44
www.beck-automation.com
Management:
Nicolas Beck
Media relations:
Daniel Merki
Phone:
+41 44 751 84 66
E-mail:
d.merki@beck-automation.com
Glaroform AG: www.glaroform.ch
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Ernst H. Furrer AG – ef cooling: www.efcooling.com
Viappiani Printing: www.viappiani.it
bfa solutions Ltd.: www.bfa.ch
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About Beck Automation AG
Beck Automation AG from Oberengstringen, Switzerland, is a world leading provider of
automation solutions for IML (In-Mold Labeling) in injection molding. Beck focuses consistently
on decorating and labeling lids, pots, tubs and buckets for various industries.
Tailored to exacting customer specifications, process reliable and economic robot systems are
built that are deployed around the globe. This consistent focus on IML guarantees that users get
the finest state of the art in terms of quality, economic efficiency, effectiveness and durability.
Run by the second and third generation of the family, the company establishes and maintains
long-term relations to market partners with a forward-looking and sustainable policy. This
strategy secures the jobs of committed and experienced staff. A traditional structure, a tried and
tested network of partners, and astute adaptation to changes form the basis for ongoing
company development and inspiration on behalf of partners, customers and staff.
Beck Automation was established in 1934 and celebrated its 75th anniversary in 2009.
Over 500 reference systems highlight the company's global significance. Approximately 35-45
system plants are shipped from the Swiss headquarters each year. Beck Automation with 37
staff achieved sales of CHF 9M in 2012.
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About Glaroform AG
Glaroform AG in Näfels, Switzerland, is a modern tool and die-making company that has been
specializing in high-performance plastic injection molds since 1986. Our 40 qualified staff
manufacture high-quality state-of-the-art molds. The molds are designed in-house by very
experienced and well-trained specialists. Extremely precise manufacturing is done on modern
machinery with tight tolerances. The latest surface coating processes guarantee the long service
life for which Glaroform molds are renowned. Injection molds and the on site hot runner system
are continuously being adapted and developed according to customer specifications and market
requirements.
In order to keep pace with rapid developments in molding, the company has largely specialized
in injection molds for thin-walled articles. The range includes margarine, gourmet foods, ice
cream, food and non-food containers, drinking cups, buckets, lids and plant pot. The products
can be designed in different formats: round, oval, square or rectangular, with or without a temper
evident closure. Today the products are primarily decorated using IML.
About Ernst H. Furrer AG – ef cooling
ef cooling in Dällikon, Switzerland, is an internationally leading manufacturer of process cooling
systems for the industry. Besides standardized equipment for cooling water, oil emulsions and
emulsions up to approx. 400kW cooling capacity, it primarily plans and produces complete
cooling systems up to 5kW cooling capacity. As part of this type of turn key project, they offer
the entire services from planning to delivery to assembly and commissioning. Emphasis is
placed on environmentally friendly concepts with energy-saving technologies, meaning outputcontrolled components in the coolant and hydraulic systems. Ventilator and pump motors,
compressors and expansion valves are adjusted electronically to the system's current operating
points. At the same time, so-called "free cooling" is becoming increasingly more popular. This
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means that cooling is achieved with cold outside air, as long as the difference is sufficient to
permit the desired medium temperature.The use of compressors is unnecessary in this phase.
In this way, power costs can be cut by up to 60%. ef cooling builds on high-quality engineering
and system design – worldwide. Custom engineering gives customers environmentally friendly
systems with a definite trend toward green technology.
Since January 2013 ef cooling is represented by a subsidiary in Germany:
Furrer Industriekühlung GmbH in Krukow near Hamburg. This ensures extensive sales and
consulting as well as comprehensive services throughout Germany.
About Viappiani Printing
From its headquarters in Segrate near Milan, Italy, Viappiani Printing supplies the international
market with a broad variety of labels, focusing on PP, PE, and PS film-based IML labels.
Viappiani Printing is a member of CTI Invest AG, a private holding company specialized in
printing, with branches in Europe (Italy, Germany and Spain), North America (Canada) and
South America (Colombia, Argentina and Brazil). Innovation and investments into the latest
technologies are guaranteed. CTI aspires to a global network of label suppliers, meaning that
customers will be able to have local support worldwide.
Established in 1929 by Bruno Viappiani, Viappiani quickly became a specialist for labels. In the
1980s Viappiani Printing was one of the first to manufacture IML labels for plastic containers on
the European market. Now, 30 years later, Viappiani Printing is a leading IML label
manufacturer for injection and blow molding processes with the goal of supplying the finest
quality labels for machines.
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About bfa solutions ltd.
bfa solutions ltd. in Schwerzenbach, Switzerland, is an engineering company that has been in
existence for over 30 years and is highly competent in industrial automation and production
processes. It has cross-disciplinary expertise and comprises computer engineering in addition to
traditional automation engineering. This enables the design and implementation of solutions at
the system control level (PLC) on the production level via data-centered capture of production
data up to the interface with ERP systems and mobile applications.
The PiSolutions product portfolio in MES ranges from capturing operating data of a few systems
of different ages and type (different interfaces, controls, etc) to networking several locations of
global companies. Services in automation system engineering are also in high demand. They
are not limited to specific industries. Established solutions from bfa solutions ltd. are particularly
popular in plastics processing, the packing industry and medical engineering.
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