New IML concept from Beck Automation

On of the most popular ways to make a good cup of coffee is to have the fresh coffee straight out of a coffee capsule. The classic disposable coffee capsule’s job is actually quite varied: from ensuring that the coffee aroma stays on even though the capsules have a long shelf life. Also, the capsule needs to ensure strong brand recognition and provide information about the contents. Once used, the packaging should be disposed of easily while demonstrating that it is environment-friendly, both during manufacture and when in use. 

 

The brilliant print quality of In-Mold labelling not only serves to effectively staging the product, but also has a concrete boost in sales: the customer can get an accurate picture of the content. Especially in the sensitive food industry, this fact can decide whether a product is purchased or left on the shelf. What might seem straightforward at first glance is becoming increasingly difficult to communicate to consumers – a good example of this is conventional aluminium capsules. The environmental awareness of consumers has noticeably been on the increase in recent years. A Polylactide (PLA) injection moulding solution with IML decoration could be just the right answer. This saves resources and gives the packaging a premium look, according to Nick Lewis, Beck Automation Americas which stresses that: “Visually appealing packaging with IML gets biocompatible.” 

 

 

 

Biocompatible strength of PLA material

IML, when combined with environmentally friendly PLA material, a synthetic polymer, offers a new way to reposition disposable coffee capsules and to enhance the appearance of the product. PLA is obtained from renewable sources, such as corn starch. This makes PLA a biocompatible raw material. This approach is also a contribution to better achieve the sustainability goal of the providers. The sweetish smell is more reminiscent of the cornstarch contained in it than molten plastic. Low moisture absorption ensures easier storage and high UV resistance, as well as severe flammability are practical properties for a variety of applications. In general, PLA has mechanically good properties such as high surface hardness, rigidity, and high modulus of elasticity (tensile strength), but only moderate impact resistance.

 

With this increasing demand in mind, Beck Automation set about developing an IML machine for high-quality plastic coffee capsules. The new machine shall premiere in the US when it is presented to the public at the NPE 2018. The result of this innovation is a highly dynamic, precise and operator-friendly machine for IML decoration. This way, the disposable coffee capsules are both more environment friendly and look more premium, too.

 

Single-serve capsule IML machine  

The exhibit at the NPE 2018 trade fair in Orlando is a four-cavity IML machine. The machine architecture shows that machines with much larger numbers of cavities are also possible for higher output rates. For example, in 2016 Beck Automation successfully commissioned several solutions for 32+32 stack molding machines, followed by a 32-cavity IML Single Serve Capsule machine in 2017.  The coffee capsules shown are inserted into a four-cavity mold from Fostag Formenbau in Switzerland. Nick Lewis from Beck Automation Americas states a target cycle time of 6 - 7s. The Polylactide (PLA) labels are produced by Verstraete, the Belgian IML label specialists. The IML-system also includes a quality assurance module to perform barrier checks from IMDvista. This turnkey option opens a high level of quality and improved added value. A high-precision and fast Netstal ELION 1200-250/55 serves as the injection-molding system. It is fitted with servo-electric drives for all components and is absolutely clean and quiet in operation. Its compact design, high shot weight precision, rapid closing speed and reproducibility, make it a perfect match for Beck Automation's IML machines. 

 

Beck Automation at the NPE 2018: South Hall Level 1, Expo Hall, booth S35146 (SWISS Pavilion)

 

Beck Automation AG

Tel: +41 (0) 44 751 84 44

Email: beckautomation.americas@cogeco.ca

Website: www.beck-automation.com