3D IML w/MuCell
	Brand Owner: PACCOR Packaging Deutschland GmbH Designer: PACCOR Packaging Deutschland GmbH Machinery Manufacturer: Netstal-Maschinen AG Materials: N/A Molder: PACCOR Packaging Deutschland GmbH Moldmaker: Plastisud
Company Entering Design - Processor: Trexel, Inc. Product Description: The 3-D in mold label is processed with an injection-molded tub made of expanded PP. Gas-filled cavities, created by the migration of nitrogen introduced by controlled use of the MuCell process, between tub and in mold label provide a soft touch effect and can be used for forming more complex surface structures right up to Braille writing. At the same time, these cavities can have an insulating effect for hot and cold usage. The base tub is also designed with a physical foaming technology making it lighter and less costly to produce than a solid tub. Imagine the possibilities offered by this innovative design.
Why is the product innovative? 5 Key Attributes: 3D graphic, MuCell, Film Technology, Design Freedom and Lower Production Costs 3-D Graphic: Standard IML labeled products provides the ability to incorporate a wide variety of graphics based on printed labels. It’s also possible to create faux 3D effects through the printing process. However, due to the extreme conditions in the mold, 270C melt temperatures and 20,000 psi injection pressures, any true 3 D graphics incorporated in the label prior to molding would be compressed and destroyed. MuCell: This 3-D IML container is a variation on the SLIM technology introduced by Veriplast 3 years ago. SLIM technology combined the MuCell process with a thin wall label to produce an IML container with reduced weight and cost. The 3D IML container combines the MuCell process with a unique label construction which incorporates selective masking to create areas without adhesion to the molded substrate. On molding, the nitrogen used as the physical foaming agent in the MuCell process creates a microcellular structure in the polymer. Incorporated in the molded part is a level of excess nitrogen that then migrates out of the part. Film Technology: Where there is adhesion between the label and polymer, the nitrogen migrates through both structures as in all other IML applications with MuCell technology. Where there is no adhesion by design, the nitrogen accumulates between the polymer substrate and label causing the label to bulge. By creating patterns on the back of the film with masking layers, the deformation of the label can be matched to text as in the above or to other design features. This has the effect of creating a true 3 dimensional graphic effect through IML. - Design Freedom is possible. This application is unique in that it is for a thin wall package however, the benefits achieved from microcellular foaming can be applied on a broad scale. By achieving both a 10% reduction in material viscosity as measured by hydraulic injection pressure and a 30% reduction in clamp tonnage by using the gas expansion to perform the function that in solid molding is done by the pack/hold phase, the container was reduced in wall thickness to give a 9% weight reduction through design and still achieve a 4% density reduction (13% total weight reduction). This compares to the initial design which allowed for 6% density reduction. Enhanced design freedom, thickest wall section at end of fill (sealing lip functionality). Through design, the new container met all compression and drop tests. It is important to understand that injection pressure is driven by wall thickness and material grade. A viscosity reduction from the MuCell process enables additional thin walling compared to solid in the same machine size. When reducing wall thickness with the MuCell process the clamp tonnage will increase but still remains significantly below the tonnage of solid molding therefore the thin walling can be achieved in the same machine size. Lower Production Costs - 13 % total less material (cost, sustainability) though MuCell capable design and foaming - 36% clamp tonnage reduction, 550 to 350T (lower cost molding machine, lower operating cost) - Higher cavitation possible in same size molding machine - Elimination of warpage (reduced scrap) on sealing lip (better seal with lid) - 15% nominal wall thickness reduction to 0.34mm without increasing required clamping force. - 15% lower injection pressure (ability to thin label, lower cost, less ink wash out) • Additional thin walling up to 15% in same machines • Improved IML performance • MuCell makes a big difference with IML because the lower pressures create less distortion on the labels. In some cases, thinner lower cost labels can be used • Better Core Stability • More uniform part • Less wear and tear on tool • Possible Cycle Time Improvement • Favorable tradeoff between hold times and cooling times • Improved Label Performance • Less shifting / fewer rejects • Thinner Container and/or Lighter Container
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