How to Produce the IML Yogurt Cups Automatically?
The IML Yogurt cups are now the top choice packaging solution for the premium Yogurt products around the world. To produce an IML cup for Yogurt we'll follow the process of material slection Polypropylene (PP), the IML label preparation, injection molding, quality inspection and packing. Here in this article we'll take the SWITEK 2 in 1 IML Yogurt Cups Auto-production system as an example to discuss the ideology of how is an IML Yogurt Cups auto-injection molding system designed and what's the advantages to have the IML Yogurt cups produced by such a system.
System Layout
System Configuration and the Functions of Each Unit
To minimize the investment of the IML project and maximize the capacity of each function unit, the new IML Yogurt cups auto injection molding system has a configurations of 2 high speed injection molding machine + 2 side entry IML robot + 1 vision control system + 1 packing system. And with a layout design customized according to the layout of the workshop, it'll help to minimize the floor occupation of the IML Yogurt cups auto-production system.
- High Speed Injection Molding Machine: The injection molding machines are the core of the IML Yogurt cups auto production system. We have two high speed injection molding machine to handle the injection molding production of 12 + 12 cavities of IML Yogurt cups at a cycle time of around 7s.
- High Speed Side Entry IML Robot: The IML robot here is the SWITEK new high speed IML robot SW833-S6 of which will handling the in mold labeling, parts picking and have the IML Yogurt cups lined up on the chain plate line for quality checking.
- The Chain Plate Line: It's a custom made one for the IML Yogurt cups production system to make it adaptable to the layout of the workshop and have the Yogurt cups pass through the Vision control system one by one.
- Vision Control System: The vision control system in the IML system is for the quality inspection of the IML Yogurt cups which will check the defects such as insufficient injection, black dots, ill labeling etc. We'll have different configuration of the cameras according to the quality checking standard requested. After inspection, the good IML cups would be pass to the next station to be stacked and the no good parts to be rejected.
- The Stacking Unit: The staicking unit will have the good IML Yogurt cups lined up again and well stacked according to the requirement and be prepared for packing. It's a very important part of the injection molding automation system.
- The Packing Unit: The packing unit in this system is to have the well stacked IML Yogurt cups film or sleeve packed and sealed. The packing machine here would be custom made according to the requirement of the customer.
Other than the standard functions of the system, we'll also provide optional functions such as productiond date printing, vaccum up the bag packed IML yogurt cups, have the IML Yogurt cups carton loaded instead of bag packing etc. to tailor make the system according to the special requirements of our clients.
The Advantages of the IML Yogurt Cups Auto Production System
The 2 in 1 IML Yogurt cups auto-production system will produce the IML Yogurt cups automatically with quality control and packing, it'll have the advantages below:
- Labour Saving: The IML Yogurt cups would be produced automatically from injection molding to packing and will help to reduce the man hours in the production process. The labour shortage is now a universal problem of the injection molding plant owners and an automation system would be a perfect solution.
- Quality Guaranteed: The vision control unit of the automation system will guarantee a 100% inspection of the IML Yogurt cups produced according to the quality standard of the Yogurt producers.
- Reduce the Waste: With advanced AI study technology, the vision control will reduce the rate of false detection and help to reduce the wast of the material in production.
- Easy Integration Into a MES System: Each of the automation system can be easily integrated with a MES system via an universal protocol for a digitalized management of the IML Yogurt cups production process.
Some Tips for the Preparation of an IML Yogurt Cups Injection Automation System
An automation system for IML Yogurt cups production sounds exciting but anyway it's a complex system of big investment, you can kip tips below in mind while preparing an automation system for your IML project:
- Only for Bulk Production: I was asked many times is it possible to have one automation system for a couple of similar products because they have so many molds available and have to produce different parts in the same injection molding machine since my joining of SWITEK Automation in 2017. I do want to say "YES" but unfortunately the answer is "NO." Any automation system would be a custom made one according to the mold design and and the injection molding machine and not be exchangable for different mold. It would be suitable for the non-stop production of the same cup.
- Expected Daily Output: The daily output of the automaiton system are a result of precise calculation and evaluation, it's the guideline of the machinery slection for the automation system.
- The Quality Standard: For an automation system with vision control, the quality standard of the parts will provide a guide line of how many cameras to be installed for the vision control system and the image processing capacity of it either.
- How to have the Cups Packed: It's the guideline of what type of packing machine to choose for the automation system.
Anyway, far from be "Smart" system of handling a complex production process perfectly, an automation system is rather to be a "Stupid" system to repeat a "Simple" production process faster and efficiently in a labour intensive industry. For any more question about a "SMART" automation system for IML Yogurt cups injection molding, please feel free to contact me via Wechat/WhatsApp below, I'm working with SWITEK R&D team to provide you with a turn-key solution.
