IML and decoration | Innovation
Right: Vision systems are increasingly
being integrated into IML
production systems,
according to
Müller. Camera placement and lighting is critical to achieve
optimum results
Label options As far as labels themselves are concerned, processors wanting to dip their toes in the water can now also avail themselves of Verstraete’s digital printing system, which can be used to produce very short runs. The company will print as few as 50 copies of a label and ship them from Belgium within two days. While most IML systems use pre-cut labels, system
developers such as CBW Automation see a place for roll fed IML - where the label is cut from a roll at the press – in applications where precision placement is critical. CBW specialises in high speed complex IML automation and has developed applications for packag- ing as well as for the medical sector. “Roll fed IML is a key necessity for accuracy in
medical syringe labels and for barrier labels, for both of which CBW has now built systems,” says CBW general business manager James Swim. “We have built many systems with pre-cut labels and we can be very accurate with them also. What we have found is that when we are working with a 16-cavity system, running in the six-to-seven second overall cycle range with very small labels, the consistency of accurate placement is improved with roll-fed labels.” Swim says the roll-fed technology provides more
control over the cutting, picking, and placing of the labels. It also avoids the slight variation in label placement and location in the magazines, which is especially important for very small labels being wrapped around a syringe body. CBW also cites differential shrinkage issues with
multilayer barrier labels—PP/EVOH for example— which can cause curling of the labels in the magazines. “With roll-fed, these labels are cut at the press and immediately held on a vacuum blanket for picking to place on the mandrels, so the curling of the labels is not an issue,” Swim says.
Improving vision Over the last few years, the presence of vision systems on IML automation systems has become more prevalent, says mould and robot maker Müller. The company cites the need to reduce overall cycle time and overall labour costs for this, as well as the significant improvements made in vision system performance and technology.
34 INJECTION WORLD | June 2014
Modern vision system performance is capable of inspecting parts within the cycle time on multi-cavity production systems, avoiding the potential risk of inspection becoming a bottleneck in the process. Processors can choose from various types of vision systems, ranging from barcode readers, through colour sensors and smart vision sensors, to the latest advanced vision sensors. Users select the technology based on the level of assurance required - barcode readers and colour sensors doing little more than checking for the presence of the correct label while smart and advanced systems provide more functionality. Smart sensors use CCD cameras in conjunction with an image processing source, and can carry out colour detection, edge measurement, shape search, code reading, character verification, and more. “These sensors will be ideally used for simple application, and have an excellent price/quality result ratio,” Müller says. Advanced vision systems go beyond this, and can be
used to check for smears, scratches or folds in the label, the width of the gap in the label seam, and for short shots/flash on products. They can be used on high cavitation IML applications, and up to eight high resolution cameras can be connected to the controller, making them the optimal choice for precise and full product inspection. The presence of vision systems will continue to
increase in IML applications, Müller believes. But it will always be critical to identify what needs to be inspected. “It is critical to test different sensors in conjunction with different lighting techniques in order to optimise the inspection. The location of the vision system must be carefully considered in the design phase in order to minimise the costs but at the same time optimise the results.”
www.injectionworld.com
robot removed banderol labels from a vertically-mount- ed label magazine before inserting them, with the help of a dummy core, into the cavity of the fixed half of the mould. Removal of the finished bucket and label insertion were performed simultaneously. Even though numerous movements were performed in and around the mould, it was open for less than 2.5s.
s
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