IML meets complex challenges

The global in-mould labelling (IML) market is experiencing rapid developments as demand for packaging products swell. In its report, Future Market Insights (FMI) stated that global IML market is estimated to reach  $ 967.6 million by end-2017, and is expected to expand at 3.2% yearly over the period 2017–2027 to reach $ 1.32 billion by end-2027. Some of the key trends defining the global IML market include adoption of digital printing for in-mould labels, use of barrier in-mould labels, IML inspection technology, innovation in offset and digital printing machines, and type of material used.

 

Ready in a ‘flip’  

One recent innovation in IML technology was adopted by Chobani yogurt which offers its yogurt in a single packaging but with two ingredients clearly separated. Developing the packaging was a highly complex challenge technically, but thanks to the possibilities of IML, an attractive and flexible solution was created.

 

In 2017, Chobani Australia launched the Flip product range, featuring products that combine Greek yogurt with a dry, crunchy mix-in. Chobani needed a smart packaging with two compartments so that the consumer could combine the ingredients for consumption by ‘flipping’ the container, according to John Williams, New Product Development Manager, at Chobani. The Chobani Flip is geared towards consumers who want a better afternoon snack that satisfies their sweet and crunchy cravings, but isn’t as naughty as chips or a chocolate bar. 

 

In developing the IML packaging, Chobani decided to team up with Australian injection moulder PakPot, which specialises in turnkey IML solutions for FMCG brand owners. Their goal? To develop IML packaging that makes the difference on store shelves and offers brand owners a unique point of difference. The flip design is one of a kind because it is a twin injected polypropylene tub with a live hinge that is decorated with a Y-shaped IML label, with the injection gated through the label by means of a hole. 

 

It took approximately 12 months between the initial idea and the finished product, with extensive testing conducted during the period. There are comparable IML products with two compartments and wraparound IML labels on the market. But, for this product, the team designed a Y-shaped IML label: the legally required information is stated on the bottom of the packaging, while the sides and top are used for marketing and branding purposes. The challenge was to properly analyse the polymer flow, since double injection automatically causes a stress line where the two materials meet together (a “cold Weld stress joint is formed”). It was critical that this stress line would not end up along the live hinge of the packaging.  

 

As Bart Schatteman, Regional Sales Manager for Asia and Australia at Verstraete IML, explained: “Verstraete IML’s greatest accomplishment in this project? The development of a Y-shaped IML with a central drill hole that allows the injection moulder to inject in the center section without obstructing a substrate, so that the end result is of excellent quality and with minimum waste production.” In this project, Verstraete IML provided possibilities offered by IML packaging. During the IML process, packaging is produced and decorated in a single step so there is no longer any need to store blank packaging, thereby eliminating both storage and transport costs.

 

 

The Chobani Flip features a Y-shaped IML with two separate sections.

 

Longer life assured 

Another important development is in the area of ready-to-eat, single-serve soups which require that content of the packaging remains healthy, tasty, ready in no time, and perfectly customised to the consumers’ needs. The shelf life of this type of product usually cause some worries as it can start to go bad once the soup comes into contact with oxygen. 

 

That is a challenge that injection moulder ITC Packaging and Verstraete IML dealt with very concretely when Spanish food producer Dulcesol approached them with the request to provide an innovative solution to its single-serving soups. Storage wasn’t the only requirement; the packaging for the Naturcrem creamy soups had to be aesthetically distinctive when on shelf. Thus, innovative Naturcrem IML packaging, using the IML label with oxygen barrier, radically was developed to reduce that risk.  

 

As the Dulcesol Group marketing director, Paco Olaso, said, the project was not taken lightly: “Value for money is in our corporate DNA,” according to Mr. Olaso. “First of all, this is expressed in the products themselves. For example, our new Naturcrem creamy soups are completely organic; there are absolutely no preservatives. The packaging must tie in with this perfectly, by being visually attractive and maximally guaranteeing the quality of the soup. That’s why we contacted our long-term partners at ITC Packaging; we know that their packaging comes with added value. Together, we ultimately developed an attractive packaging with an IML oxygen-barrier label from Verstraete, which extends the products’ shelf life without requiring refrigeration. This results in significant energy savings. In addition to that, the look is impeccable; the pentagonal base and round, open top makes the packaging an innovative format in all respects within the ready-to-eat creamy soups segment.”

 

For ITC Packaging, the Dulcesol project aimed to launch products in an entirely new segment: ready-to-eat, natural creamy soups. The challenge was to develop individual packaging that is microwave-safe and has an oxygen barrier, given that the product is 100% natural and doesn’t contain any preservatives. IML was the answer because it not only met all of those requirements, but the packaging can also have a 360° decorative, non-removable IML label.

 

The critical element however, was the oxygen barrier in the IML label. This barrier ensures that Naturcrem soups have a shelf life of up to one year without refrigeration. For Verstraete IML’s part, an IML label with an oxygen barrier reduces the oxygen permeability of IML packaging, in particular by making use of an EVOH layer in the IML film. This means that the OTR value, the extent of the oxygen permeability, is up to 100 times less compared to packaging with a standard IML label. But more than that, the labels also had to withstand pasteurisation. The heat and humidity involved in the pasteurisation process meant that this would be challenging. To be able to achieve this, Verstraete IML utilised a combination of specific inks, a special lacquer, and a special pasteurisation-resistant oxygen barrier film. This meant that the labels on the IML packaging would maintain their quality and look, even after pasteurisation. 

 

An additional, important requirement for the development was individual portions as millennials want responsible foods with a minimum of trash and food wastage. This Naturcrem is able to meet as the IML is 100% recyclable, given that the packaging and the IML label are made from the same material.