DIBBIOPACK- 280676 D2.11 Completely characterisedIML technology processing behaviour of new biodegradable

materials

Proprietary rights statementThis document contains information, which is proprietary to the DIBBIOPACK consortium. Neither this document,

nor the information contained herein, shall be used, duplicated or communicated by any means to any thirdparty, in whole or in parts, except prior written consent of the DIBBIOPACK consortium.

Document title: D2.11. Completely characterised IML technology processing

behaviour of new biodegradable materials

Due delivery date: 31/08/2014

Nature: Deliverable (Technical Report)

Project Title: Development of Injection and blow extrusion moulded

BIOdegradable and multifunctional PACKages by

nanotechnology: improvement of structural and barrier

properties, smart features and sustainability

Project acronym: DIBBIOPACK

Instrument: Large Scale integrating Collaborative Project

Thematic Priority: FP7-NMP.2011.LARGE.5

Grant Agreement: 280676

Organisation name of lead contractor for this deliverable: TECOS Slovenian Tool and

Die Development Centre

Dissemination levelPU PublicPP Restricted to other programme participants (including the Commission

Services)RE Restricted to a group specified by the consortium (including the

Commission Services)CO Confidential, only for members of the consortium (including the

Commission Services)X

DIBBIOPACK- 280676 D2.11 Completely characterisedIML technology processing behaviour of new biodegradable

materials

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PUBLISHABLE EXECUTIVE SUMMARY

In mould labelling is a technological process for labelling a moulded part during theinjection moulding processing. In the in mould labelling process, a label or appliqué isplaced in the open mould and held in the desired position by vacuum ports,electrostatic attraction or other appropriate means. The mould closes and moltenplastic resin is injected into the mould where it conforms to the shape of the object.The melted polymer envelopes the label, making it an integral part of the mouldedobject. In mould labelling (IML) however require proper mould design andconstruction for accurate label placement and reliability of the IML processtechnology. Besides the injection moulding machine, process parameters, and thequality of the labels used, the quality of injected IML parts is significantly affected bythe injection mould, which must be deliberately designed and carefully constructed.Perhaps the most complex feature of IML is the way the label is held in place in theinjection moulding tool and the gate location, which is critical because the materialhas to enter and flow into the cavity and approach the label in a specific way toachieve the quality required. The objective of this technical report is to provide aninsight into the accurate design and precise construction of mould for IML processingtechnology. For this study, the testing injection mould was equipped with vacuumports for holding the label and completely re-designed for optimised IML processingof biodegradable materials. Labels will be obtained by die-cutting from a mastersheet of PLA films, by using special designed blade matching the label formats withmost precision.

From the results shown in this deliverable it was realized that In Mould Labelling

(IML) process technology is one of the most demanding technology in the injection

moulding process. Adding the usage of the biodegradable material and

biodegradable foils just adds to the problem. The single most difficult problem is the

brittleness of the foils which means that only lowest setting of melt flow can be used

(e.g. low injection and packing pressure, low velocity of the melt...). In order to fit all

the special requirements of the biodegradable labels the mould had to be refitted

several times, to finally get the optimum results. However we find that corona treated

labels with thickness of 60 microns and labels with well dispersed calcium carbonate

are very promising for IML process technology. By a proper mould insert designing

these labels represent the optimal material formulations that can be processed within

wide-ranging processing IML window. For EB_IML the best compatibility with main

material represents cellulose labels NV 948. Regarding the new labels of PLA

material none of them attaches as well as the NV948, but in the other hand NV948 is

a commercial product and the PLA labels are prototypes that are nevertheless very

promising on its behaviour.