Sven Kitzlinger, senior application manager medical at Arburg, discusses using IML labels with function integration in the medtech industry.
Arburg
Products decorated using in-mould labelling (IML) are now standard in the packaging industry. For applications in the medical sector, on the other hand, it is not just the decor that is important, but above all precision and added value by integrating functions.
At the Fakuma 2023 trade fair, a newly designed application was on display that fulfils precisely these requirements. Using the example of centrifuge tubes, the great potential of the IML process for use in medical technology and the pharmaceutical industry was demonstrated.
The partners involved in this innovative project are Arburg (injection moulding machine), Beck (automation), KEBO (mould), MCC/Verstraete (label) and Intravis (camera inspection). Together, they have contributed their expertise to developing and realising an IML concept that is set to generate momentum in the medical sector.
1. Automation enables precise positioning
The narrow centrifuge tubes, each with a capacity of 15 millilitres, place high demands on the positioning of labels. While IML decors for packaging products are usually positioned with an accuracy of around 1 to 1.5 millimetres, the "print to cut" distance here is only around 0.2 millimetres. Our partner Beck played a large part in this, by utilising the technical possibilities in automation to the full. An automated system with a label adjustment head is used to align and apply the labels precisely. Optical control is via an Intravis camera system integrated into the Beck automation system.
2. Integrated functions create added value
Labels for medical products are particularly interesting due to the possibility of integrating functions. The centrifuge tubes are fitted with a scale, for example, which indicates the exact fill level. Temperature-sensitive thermochromic printing, which changes colour as soon as the temperature rises above seven degrees Celsius, can be applied to detect any interruption in the cold chain at a glance.
3. Monomer material is recyclable
The functional PP labels with a wall thickness of 57 micrometres are not only scratch-resistant, but also contribute to stability, so that the amount of material required for the PP tubes can be reduced accordingly. Downstream work steps such as conventional printing or gluing are no longer necessary. This enables time/cost-efficient production. In addition, the adhesive-free product made of monomer material can be recycled without any problems.
4. 100% traceability
Information on recycling and warehouse management can also be added to the product via an integrated code. Further added value of the clearly labelled IML labels: the process, quality and patient data can be traced back 100% for each individual part. Such intelligent linking of data is essential for smooth digital communication between patients and doctors or home care applications.
5. Efficient injection moulding process
At Fakuma 2023, the 15-millilitre centrifuge tubes made of PP were injection moulded with an 8-cavity mould from Kebo in a cycle time of around ten seconds. At the centre of the production cell is an electric injection moulding machine with a clamping force of 1,500 kN in cleanroom design. The high-performance machine in the "Ultimate" performance variant is designed for fast and demanding processes and fulfils the requirements for production in cleanroom class ISO 7. The finished products are discharged as good parts, bad parts or test parts via three flaps.
6. Rejects reduced by a factor of 10
The production of the ready-to-use products and the application of the IML labels in just one injection moulding process also made it possible to reduce rejects by a factor of 10. In a real application, the concept could be expanded further by integrating screwing of tubes and packaging in tubular bags into the production cell.
Conclusion
Due to the combined expertise of machine, tool and IML technology experts and automation, an IML application has been developed that is setting standards in the medical industry. It enables precise, space-saving and cost-efficient production of IML products - without any additional hygiene risk or work for staff and logistics.