Driven by its underlying principle to make
good things better, the company did
extensive and ongoing market research with
parents and carers to scope out how they
could structurally improve upon the rigid
pop up lid concept.
Rick explains: “Wipes are a classic on-the-go
product where convenience and accessibility
are paramount. During the design and
trial phases, users repeatedly emphasised
the dexterity challenges they face when
changing or cleaning a wriggling child.
Above all else, they desired a secure lid that
stopped wipes from drying out to save on
waste, yet could be opened and closed with
one finger.”
To maximise post-consumer recycling efforts,
Amaray made the intentional decision to
use polypropylene. “It means that the entire
component - lid and label - can be recycled
after use,” says Rick.
In order to deliver this uncompromising
design, the lid needed to be moulded
as a single component and decorated
and assembled in a seamless process.
From an injection moulding perspective,
using a 12+12 stack mould although
more productive, presented a tooling and
processing challenge. Sumitomo (SHI)
Demag’s UK packaging expert Kevin Heap
explains: “To create the flip-like hinge was
challenging in itself, as the tooling needed
to accommodate varying depths of raw
material. Unlike a single face tool, the
polymer is injected in the centre between the
two plates and has to be evenly distributed in
all 24 cavities.”
Additionally, using a two-face 12+12
stack mould in conjunction with the IML
system means that 24 cavities are opening
at the same time, with a Waldorf Technik
side-entry robot placing labels accurately
within fractions of a second. “Typically,
packaging moulders use a single face mould
with a maximum of twelve cavities when
integrating an IML system, so Amaray’s
installation doubled the complexity. To insert
labels on both tool faces required a much
larger robotic system,” emphasises Kevin.
In addition to the
ultra-high speed
580-tonne El-Exis SP,
the Sumitomo (SHI)
Demag team supplied
fresh thinking to
achieve the best
design, moulded in
the most productive
and cost effective way
possible
MULTI-TASKING ROBOT
Given that the El-Exis is the world’s fastest
packaging machine, robotic speed was
equally important. The Waldorf side-entry
robot serves two purposes. As well as
inserting the label into each cavity before the
plastic is injected into the mould, it has to
retract and then re-enter the moulding area
to remove all 24 lids, closing them before the
plastic hardens.
The robot then manoeuvres around to place
the lids on a conveyor where the dimensions
and label are fully quality checked. The vision
system, cameras and software were supplied
by Mevisco, with Rick hailing their support and
commitment to the project as being excellent.
If parts fail to meet the specified criteria they
are rejected from the line by air blasts without
interrupting the production flow. Utilising the
latest Smart Factory innovations to ensure full
traceability, the checking system monitors
and captures the data of total parts produced,
parts rejected and the reasons for those
rejections.
Once the full quality check is complete, the
lids are stacked and bound in-line, creating a
brick of nine stacks which are wrapped and
palletised ready for shipment.
“For moulders that are seeking to maximise
profitability and productivity - particularly
for high quality, decorated yet low margin
branded lids - stack moulds provide an
increasingly attractive option,” notes Kevin.
“With a stack system of this scale, moulders
can get more production output per square
metre, as well as saving on utility and
maintenance costs.”
“Commissioning the stack mould was a bold
move on our part. However, it massively
increases our moulding capacity in each cycle,”
adds Rick.
100% UNIQUE
While some moulders might be content
following the rules, engineering something
that has never been attempted before is
always exhilarating, claims Rick. “It requires
dedication and open communication, with
engagement across all suppliers. For a mega-
In keeping with their ‘Making Good Things,
Better’ philosophy, the Amaray wipe lid is
uniquely designed and manufactured to be
opened and closed with one finger
project like this there were so many aspects
to consider. Yet, our uncompromising attitude
was worth the effort as we have engineered
a new process and technique for moulding
packaging lids in high volumes.”
During some parts of the process, the tooling
and machine was being built in tandem with
developing the lid design and consumer
focus groups, says Rick. “Creating something
new, especially such a revolutionary
production line, requires a different mindset.
Development is exponential. If you challenge
yourself to think differently, you can be more
disruptive. It’s only when you start to put the
pieces together, adjusting the requirements
as the project evolves and consumer feedback
is generated, can you really refine the process.
Thanks to everyone’s engagement, this project
has been an absolute privilege to work on.”
The entire Amaray team has closely watched
the project unfold, with live production
commencing towards the end of 2018. “Such
was the excitement among colleagues, we
were counting down the days to launch,”
exclaims Rick.
“There are several examples in Europe
of moulders using 8+8 stack moulds for
producing IML margarine lids in high
volumes,” adds Kevin. “However, using a 12+12
stack mould, Amaray’s line really has pushed
the packaging boundaries.”
Sitting directly in view of Amaray’s conference
suite, visitors to the Corby plant are quick to
comment on just how ground-breaking the
production line is. “From a functionality and
user perspective, the single push button wipes
lid is new and innovative. Equally inventive is
the process for manufacturing them in such
vast volumes,” ends Rick.
www.amaray.com
Issue 42 PECM
103