Marbach co-operation with Weidenhammer: Brand-new insert technique is revolutionizing...
... in-mould labelling
For eight months now, Weidenhammer Plastic Packaging GmbH is manufacturing cups and lids for “Rügenwalder Teewurst” (smoked pork paté) at their production site in Zwenkau near Leipzig (Germany) by using both tooling and in-mould labelling (IML) system from Marbach moulds & automation GmbH. A brand-new insert moulding technique developed by Marbach provides pefectly attractive product decoration as well as some further advantages.
Weidenhammer is one of the world‘s leading manufacturer of composite cans, composite drums, luxury tubes and plastic containers. Together with Marbach moulds & automation, tooling and handling system supplier for the injection moulding industry, Weidenhammer Plastic Packaging in Zwenkau has been running numerous projects over the last 4 years.
Completely different jobs such as containers for ice-cream, cheese packaging or sausage packs have already been realized.
Carrying out the latest “Rügenwalder Teewurst” project both of these innovative companies are treading new paths in in-mould labelling.
But why did Weidenhammer choose Marbach from all suppliers? “In this case, it was an easy decision. On the one hand, because we got to know Marbach as an innovative partner for sophisticated projects in the past few years. And on the onther hand, Marbach has a lot of experience of tooling and IML automation providing excellent insertion accuracy. Thus, the perfect partner for a project of this magnitude”, says Operations Manager Maurizio Conte.
The Rügenwalder project has started in July 2009. A cup, which has so far been produced with the thermoforming method with sleeve technology (shrinking of decoration), should now be produced with IML technology. A specific challenge was that the existing cup layout was not allowed to be changed.
Maurizio Conte: “This customer requirement made it necessary to utilize a totally new IML technology. Due to the joint development of Weidenhammer and Marbach the existing limits of in-mould labelling have been re-defined. Now, new injection moulding applications are possible which could not been realized before.’”
Marbach exactly knows Weidenhammer‘s high requirements. Holger Kast, General Sales Manager at Marbach moulds & automation: “This project was a big challenge for us. Because when using standard IML decoration the bottom of the cup must be provided with a small foot.” However, this was not possible due to the pre-defined cup layout of the Rügenwalder project. Kast continues: “After numerous deliberations and tests a joint solution was found and verified by prototypes later. So, we could do without the classic foot at the bottom because the banderole and the bottom label cover the entire cup. Marbach would not be Marbach if we had not further optimized this insert moulding technique and consequently considerably increased the system’s efficiency. And, in the meantime this insert moulding technique has been patented.“
The test results could be applied to the production tools and automation without any changes.
Approximately 5 months after the start of the project the production facilities, which had been matched together with the injection moulding machines on Marbach‘s premises, were moved to Zwenkau.
Now, the products can be injected, decorated and screened by a camera system in one processing step there.
Cup and lid facility are enclosed in a cleanroom to meet Rügenwalder‘s high standard of hygiene. And, all facilities (robotics as well as injection moulding machines) are lubricated with food-safe grease (NSF H1 registered) to leave no room for doubts about hygiene.
In the future, Marbach will continue the trend toward innovative products. Together with Weidenhammer, for example, Marbach has projects in the pipeline that will have significant influence on the packaging market. (Karl Marbach GmbH & Co. KG)