Overview
In mould labeling technology (IML) integrates the label into the container during moulding, creating a durable, premium finish that’s easy to recycle. By using mono-materials like polypropylene (PP) or polyethylene (PE) for both label and container, IML improves sustainability, reduces waste, and streamlines production. This guide explains IML’s history, components, process, benefits, challenges, applications, and future trends.

What Is In Mould Labeling Technology (IML)?

In mould labeling technology places a pre-printed label inside the mould before plastic is injected (injection moulding), blown (blow moulding), or formed (thermoforming). Heat and pressure fuse the label to the container, delivering:

• Long-lasting graphics that resist scratches, moisture, and chemicals
• Seamless, edge-free aesthetics
• Mono-material packaging for easier recycling

Brief History of IML

• 1970s: Introduced in Japan to improve label durability on plastic packaging.
• 1980s–1990s: Wider adoption with better moulding equipment; strong growth in Europe and North America.
• Today: Used across food, personal care, household, and emerging sectors for sustainable, high-quality packaging.

Core Components of an IML System

• Labels: Pre-printed PP, PE, or PET films designed to withstand heat and pressure.
• Moulds: Steel or aluminum tools engineered with vacuum channels and cooling systems.
• Plastic Substrate: Typically PP or PE for optimal bonding and recyclability.
• Injection/Blow/Thermoforming Machine: Precisely controls temperature, pressure, and cycle time.
• Robotics/Automation: Places labels accurately to reduce errors and increase speed.

How In Mould Labelling Technology Works

1. Label Feeding: Robots or pick-and-place systems load labels using vacuum suction.We recommend using the IVIROBOT IML robot system here.
2. Mould Closure: Sensors or vision systems verify precise label alignment.
3. Moulding:Injection moulding- Molten plastic infuses into the label under pressure. Blow moulding-Air inflates a parison against the mould, pressing the label in place. Thermoforming- A heated sheet forms over a label-lined mould.
4. Cooling: Uniform cooling locks the label to the container.
5. Ejection: Finished parts exit with integrated labels.
6. Quality Check: Vision and mechanical tests ensure bond strength and visual quality.

The Science Behind IML Bonding

• Optimal heat (typ. 180–220 °C for PP/PE) softens polymers for mechanical and molecular bonding.
• Best performance with matched materials: PP label + PP container or PE + PE.
• Surface activation (corona/plasma) and controlled temperatures prevent weak bonds or label degradation.

Moulding Methods Used in IML

• Injection Moulding: Fast cycles (10–30 s), high precision; ideal for lids, tubs, caps, technical parts.
• Blow Moulding: 360° wraparound for bottles and jerrycans; typical cycles 30–60 s.
• Thermoforming: Efficient for tubs and cups with flat/slightly curved surfaces; cycles 10–30 s.

Choosing Printing Methods for IML Labels

• Flexographic: Best overall balance for high volumes and vibrant colors.
• Offset: Premium, high-resolution graphics with fine details.
• Gravure: Consistent quality for very large runs and intricate designs.
• Screen: Durable solids, logos, and large color areas.

Design and Material Best Practices

• Match label and substrate (PP/PP or PE/PE) for adhesion and recyclability.
• Engineer moulds with:
  • Vacuum channels to hold labels on complex shapes
  • Optimized cooling to prevent warping and distortion
  • Texture options (matte, grip, embossed logos)
• Control parameters:
  • Temperature too low → weak bonds
  • Temperature too high → label damage
  • Surface treatment improves receptivity

Key Benefits of In Mould Labeling Technology

• Durability: Resistant to water, chemicals, abrasion, and temperature swings—ideal from freezer to microwave.
• Premium Aesthetics: High-resolution, seamless graphics with options for metallics and tactile finishes.
• Sustainability:
  • Mono-material packaging simplifies sorting and recycling
  • Eliminates adhesives and release liners, reducing waste
• Cost Efficiency:
  • Integrated process removes post-mould labelling
  • Lower labor and scrap; faster cycles
• Tamper Resistance: Labels are inseparable from the container, deterring counterfeiting and tampering.
• Traceability: Supports barcodes, QR codes, and RFID for supply chain visibility.

Common Challenges and How to Solve Them

• Label Misalignment: Use vision-guided robots and electrostatic pinning.
• Air Entrapment: Add vacuum micro-channels and tune injection flow to minimize turbulence.
• Adhesion Failures: Ensure polymer compatibility (PP/PP, PE/PE), apply corona/plasma treatment, and optimize temperature.
• Cost Barriers: Adopt modular moulds, scale automation in phases, and calculate ROI from reduced scrap and labor.

Quality Control Essentials

• Vision inspection for misalignment, color, and defects at high line speeds
• Adhesion tests (e.g., peel, cross-cut)
• Environmental tests (thermal cycling, chemical exposure, UV)

Top Applications of IML

• Food & Beverage: Yogurt cups, ice cream tubs, ready-meal trays; freezer- and microwave-friendly.
• Personal Care: Shampoo bottles, cosmetic jars, toothpaste tubes; glossy and tactile finishes.
• Household & Industrial: Detergent and chemical containers, durable warning labels, automotive parts.
• Emerging Uses: Medical packaging with tamper evidence, electronics with QR/RFID for traceability.

Innovations and Future Trends

• Smart Labels: QR, NFC, and RFID for authentication and consumer engagement.
• Advanced Finishes: Embossed textures, holographics, and hybrid films for premium branding.
• Sustainability Push: Compostable films (PLA/PHA), recyclable barrier coatings, circular systems with mono-material design.
• Industry 4.0: AI vision for defect detection, IoT sensors for predictive maintenance, digital twins for faster development.

FAQs About In Mould Labelling Technology

• Is IML recyclable? Yes—especially when label and container use the same polymer (PP or PE).
• Does IML increase costs? Upfront tooling and automation can be higher, but total cost often drops via faster cycles, lower labor, and reduced waste.
• Can IML handle complex shapes? Yes—vacuum channels, electrostatics, and precision robotics enable wraparound and curved surfaces.
• What industries benefit most? Food, personal care, household chemicals, and any brand targeting premium, sustainable packaging.

Conclusion

In mould labeling technology delivers durable, premium, and sustainable packaging—while improving efficiency and reducing waste. By adopting mono-material designs, optimized moulds, and smart automation, brands can meet consumer expectations and regulatory demands. If you’re considering IML for your next packaging project, start with material compatibility (PP/PP or PE/PE), robust mould design, and the right printing method for your volume and visuals.

Ready to explore in mould labeling technology for your products?

 Contact us for a tailored IML consultation, cost analysis, and prototype roadmap.