Fakuma exhibit: Injection compression molding of IML thin-walled cups

The exhibit uses a 4-cavity mold from Brink to produce thin-walled IML round cups from polypropylene (PP) using injection compression molding. The flowpath/wall thickness ratio is 380:1. For process monitoring, the mold is equipped with six high-resolution inductive position measuring and embossing sensors. Four molded parts, each weighing 10.4 grams and with a wall thickness of only 0.37 millimeters, are produced in a cycle time of 3.95 seconds. The plastic is biomass-balanced and ISCC-certified. Also integrated into the production cell is a side-entry robot from Brink that inserts the labels, removes the finished cups and stacks them on a conveyor belt.

With this particularly resource-efficient application for the packaging industry, special emphasis was placed on energy efficiency and on a part design that saves materials. Thanks to the all-electric packaging machine in combination with injection compression molding, the energy footprint is improved by 20 percent with a significant reduction in part weight from 13 to 10.8 grams. The special "Next Cycle IML" label can be completely separated from the cup's PP during recycling, so that the product can be recycled by type after use. In contrast to thermoforming, no pre-produced foils are used and no stamping waste is produced.