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erman Marbach Werkzeugbau, which supplies injection moulding and thermoforming tooling and related automation for the packaging industry, has unveiled an in-mould labelling (IML) system for thermoformed PP containers. The technology gives packagers and food companies a new high-output, low-cost alternative to injection molding IML for food packaging.

Marbach made the introduction at K recently. The Zapod2 label handling system is for tilt moulds on trim-in-place thermoformers. It consists of a linear-drive robot with one high- speed swivel head that approaches the mould from the side, placing the label in the cavity. A second robot system with an ultra-light vacuum plate drives into position while the forming process is taking place. Once the mould opens, the high-speed vacuum plate transports the finished product from the mould and moves it upward to another robot for placement on the conveyor. By reducing the time for part removal and label placement and improving the forming time, the system is capable of higher speeds compared to competitive T-IML systems, says Marbach

The Zapod2 system can be used on tilt-mould machines offered by manufacturers such as Gabler, Thermoforming Systems, Kiefel and Illig. It can be run on customary 20 to 30-cavity moulds and delivers product changeovers of 30 minutes. Marbach has installed a one-up T-IML mould on a Gabler tilt machine at its Heilbronn, Germany, testing and development centre where it works on label and part options with its partners.

The first automation system is expected to be sold later this year and production is slated for early 2011.