Injection Moulding

Injection Molding is the process of manufacturing high volume plastic products that have same shape and dimensions.

In this process, plastic raw material granules are melted under high temperatures until it becomes soft and then it is injected into mold having the shape of the product. 

Once the molten product cools and hardens the mold opens and product is released. The whole process is then repeated for required production quantity. 

In summary, the Injection Moulding cycle comprises of following 4 stages.

1. Plasticizing the resin
2. Injecting the melted resin into mold
3. Cooling the product 
4. Ejecting the product and getting ready for next cycle

IML printing is a decoration process in which pre-printed decorative labels are placed inside a mold using robots before the plastic is injected into the mold. During molding, molten plastic resin is injected into mold wherein plastic and label are fused together to form a single product with IML printing. 

  Advantages

• High printing quality
• Impact and scratch resistant
• Quick production as molding and printing is in one shot
• Ideal for mass production

Disadvantages

• Requires investment on printing plates
• High cost of label
• Not suitable for low volume printing

Dry Offset Printing (DOP) is a decoration process in which ink from rollers forms an image on flat (planographic) image carrier plate for each colour and then images of each colour are transferred (or “offset”) to a rubber blanket to form full image that in turn is printed on surface of pails. 

  Advantages

• Overall cost of printing is low
• Multi-colour printing up to 6 colour
• Very high production
• Consistent and accurate printing
• No ink odour as ink deposit is low

Disadvantages

• Initial investment on plates is high
• Limitation on printing of sharp images
• Not suitable for low volume printing

Heat Transfer Labelling (HTL) is a decoration process in which design is first printed on the release layer of label and then this design is transferred from label to the pail with application of heat and pressure. 

  Advantages

• Offers higher adhesion and durability
• Attractive printing
• Printing up to 8 colors

Disadvantages

• Cost of labels is high
• Not suitable for low volume printing jobs
• Overall printing cost is high

Screen printing is a decoration process wherein ink is transferred through an exposed screen mesh onto surface of pail. One colour is printed at a time, so several screens are used to produce a multicolored design.  

  Advantages

• Lower upfront costs 
• Ideal for low volume printing jobs
• Overall printing cost is low
• Long-lasting print on pail
• Lead time required from artwork design to printing is less

Disadvantages

• Not ideal for Dairy and Food pails
• High colour deposit may result in odour
• Time consumed for drying increases in moist environment
• Reduction in production with increasing number of colors