PROCESSING | IN-MOULD DECORATION
and certification. For instance, the Association of Plastic Recyclers (APR) has designated IML as a ‘Preferred’ labelling method for polypropylene (PP) and high-density polyethylene (HDPE) when labels of a compatible polymer are used because it is bonded with the wall of the
Above: Proell’s Noriphan HTR N 959 was used to create this climate control panel
mentation of intelligent lighting elements. Kurz says this could be used in applications such as ambient light design in vehicle interiors or custom- isable signal lights. At last year’s International Suppliers Fair (IZB) in
Germany, Kurz showed several technologies for the design of decorative and functional surfaces for vehicle interiors and exteriors. One was a front panel that is radar- and LiDAR-permeable. It was manufactured and finished in a single work step, which was made possible by Kurz’s IMD process. In combination with hybrid technologies such as laser ablation, hot stamping, or digital printing, it opens new possibilities for decorating and customising the front panel, says the company.
Recyclable option The US-based In-Mold Decorating Association (IMDA) has released a white paper that stresses the recycling advantages of in-mould labels (IMLs). It describes how in-mould technologies for labelling and decorating yield recyclable and sustainable plastic packaging for a variety of markets and applications. Topics include: an overview of in-mould labelling advantages in recycling; a discussion of in-mould technology’s sustainability factors in production environments; design guidance for recyclability; and a case study featuring a packaging application. Because the substrate used for IML and IMD
processes becomes an integral part of the finished part, this simplifies sorting and washing at recycling facilities – as there is no need to remove a paper or film label and adhesive. Instead, the IML or decora- tive film is made from the same (or similar) resin as the part – such as food packaging – meaning there is no contamination of the recyclate with a different resin or adhesive. As a result, the IML or IMD-made item proceeds through the recycling process and is reground into pellets with the bulk resin. IMD processes also eliminate adhesives – which can affect the colour and mechanical properties of recyclate. The white paper says claims about the recycla-
bility of IML and IMD packaging are supported by third-party recommendations, designations, testing
14 INJECTION WORLD | May/June 2025
package/part. APR adds that the lack of adhesive also helps recycling. At the same time, ‘Design for Recycling Guidelines’ by RecyClass has designated IML for both PP containers and HDPE containers and tubes as “fully compatible with coloured PP recycling when the amount of ink is below 1% of the total weight of the full packaging”. The white paper is available free to IMDA members.
Ink options At last year’s Fakuma, Germany-based Proell introduced several inks for in-mould decoration (IMD) and film insert moulding (FIM) applications. Its Noriphan HTR N 990/011 NC is a non-con- ductive black screen printing ink for FIM. The carbon black-free product is available for printed electronic applications. The colour shade has high optical density, an electrical resistance in the giga ohm range and is radar transmissible. It can be used for decorative prints but is mainly for multi-layer pre-printing (under-layering) for metallic and polymer conduc- tive pastes. It also meets increased requirements for thermal resistance and the demanding hydroly- sis test in the automotive industry. The colour shade has been formulated and optimised regard- ing the interlayer adhesion and shows good adhesion in compound values in the final film/ink/ injection material composition. Another grade, Noriphan HTR N 959 IR transpar- ent black screen-printing ink, is for functional touch panel applications. The shade has a black appear- ance in incident light. Under transmitted light the shades appear transparent. It is suited to IR and LIDAR transmitting areas in display and touch panel applications. At the same time, HTR N 945/546 is a special adjusted UV stabilised white, which can be used for BEV front modules. Front modules for electric cars will be decorative, multi-coloured and functional. The screen-printed ink layers are located between a film and coating compound, so the IMD/ FIM screen printing inks are protected by the transparent films and hard coat layers. However, the weathering stress on a white screen-printed ink layer is high, so a special pigmentation is needed to stabiliser the colour shade. Meanwhile, Noriphan N2K non-conductive
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IMAGE: PROELL
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