decoration | IML
Right: Camera- based vision
technology is essential in high perfor- mance IML production, according to Beck
Automation
existing stack moulds with the cavities arranged on the middle plate can be upgraded to IML operation without the additional cost of new mould tools.
Extending automation With labour costs continuing to rise in the packaging industry, many producers are looking to remove as much manual intervention as possible, according to Switzerland-headquartered IML technology developer H. Muller Fabrique de Moules. “A large percentage of IML systems now being produced and delivered include an automated boxing system on the end of the line,” says Taras Konowal, manging partner at Fame Technol- ogy Solutions, H. Müller’s agent for North America. “This transition has begun to gain momentum over
the last year and in 2015 the majority of IML systems being delivered by H. Muller Fabrique de Moules have included automated boxing,” Konowal says. The move to integrated “granule-to-box” production
is a consequence of the advances in IML automation technology. The speed of communication between the moulding machine and the robot is now extremely fast and the information transferred in terms of timing and position is highly accurate. This makes it possible to initiate dynamic robot movements that anticipate clamp opening, says Konawal, allowing the overall cycle time to be further reduced. Producing more finished parts in a shorter time
Below: Star Automation Europe’s S7 IML Flex system is designed for moulders running several different IML programmes
presents greater challenges in terms of management and means full automation becomes a much more practical and cost-effective option. “In the past operators were used to inspect and package finished containers. With the current speeds and volumes it becomes challenging, if not impossible, for a human to visually inspect parts, remove rejects, stack the good parts and pack them into boxes,” he says, adding that the powerful camera-based vision systems that are now becoming standard options on IML production systems
allow “good” production to be guaranteed. Camera-based vision systems also feature in the
latest IML systems developed by Switzerland-based Beck Automation. The company demonstrated its latest system design during the Fakuma show in Germany late last year as part of a manufacturing cell comprised of an Engel e-Motion 160 tonne moulding machine with a 2-cavity 500ml 11g PP oval container mould by Glaro- form (also of Switzerland) and its own IML automation and Omron FZ3 camera-based quality system. The compact system was running a 2.9s cycle using pre-cut 60 micron PP labels from Viappiani. Label loading and part removal was achieved in less than 1.0s. The number of cameras needed on an IML system depends on the specific application, says Beck Automa- tion Sales Manager Daniel Merki. “The structure and number of camera inspection modules depends, among other aspects, on the control requirements of the packaging unit, cycle speed and the number of cavities,” he says. Factors such as part shape and size and the point within the process that the inspection is made all come into play.
Delivering flexibility As IML projects become more commonplace there is a growing space in the market for IML automation that places flexibility over outright speed, according to Giovanni Sperandio, export sales manager at Star Automation Europe in Italy. It has designed its S7 IML Flex system for processors handling a variety of IML tasks. “We are aiming at the part of the
market that doesn’t need one product in big volumes. There are many companies that specialise in fast automation – very fast but dedicated. The advantage of our system is that it is very flexible,” he says.
24 INJECTION WORLD | June 2015
www.injectionworld.com
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66