In-mould labelling
High-quality branding of plastic protective cases
If your business uses a high volume of lightweight plastic cases, the branding potential of in-mould labelling should be an important consideration.
In-mould labelling (IML) is the process of a pre-printed label being moulded into a product during manufacture. Popular for consumer goods such as plastic bottles and tubs, IML is also widely used for plastic cases. In-mould labelling provides a high-quality appearance and durable, scuff-resistant finish.
This guide briefly outlines the in-mould labelling process, how it is applied to protective cases, alternative branding methods, and the benefits for your business.
Contents
Introduction
Origins of in-mould labelling
In-mould labelling was originally invented by a business named Owen Illinois.
Traditionally a glass packaging manufacturer, it developed the process in conjunction with Proctor & Gamble to supply pre-labelled bottles. The first application was for Head-and-Shoulders shampoo bottles.
The process became increasingly popular, particularly for consumer goods. Products featuring in-mould labelling include plastic bottles, tubs, and food containers, as well as applications such as aerospace parts and electronics equipment (smartphones, notebook computers, etc.).
In mould labelling for cases
In-mould labelling was eventually adopted by many other businesses creating moulded plastic products, including case manufacturers producing lightweight carry cases and sample cases.
There are two main uses for cases with in-mould labelling.
Firstly, for large companies with extensive sales teams, in-mould labelling allows you to add branding and graphics to your reps’ sample cases. This can help with brand awareness and convey a professional appearance during sales pitches and meetings.
Secondly, in-mould labelling is perfect for when businesses use plastic cases as added-value packaging. For example, companies selling sets of products (such as drill bits, tool or socket sets, medical devices etc.) can have branding and instructions moulded into the case, which the end user then retains for ongoing storage and transportation.
In-mould labelling process
How in-mould labelling works
The in-mould labelling process works as follows:
1: A heat-resistant material is printed with the required design using suitable inks. Heat-resistant coatings are also applied.
2: The label is then added to the mould. Typically, it is held in the correct position using a vacuum or static electricity.
3: The plastic material used for manufacturing the case is added via injection or blow moulding techniques.
4: Once cooled, the plastic case with the label, now integral to the material, is removed from the mould.
5: The case can now be used for its intended purpose.
Plastic case use
Which cases is in-mould labelling available for?
It is possible to use in-mould labelling as part of two manufacturing processes: injection moulding and blow moulding. Many manufacturers use these processes to produce their range of protective cases.
Injection-moulded plastic cases are manufactured by injecting heated plastic into a mould. Cases using this process, and which can therefore benefit from inmould labelling, include Hofbauer Maxibag, Minibag, and Xtrabag, Rose Plastic Ergoline, Maxado SPI cases, and WAG Tekno and Twist cases. These are all lightweight, single-wall cases.
Blow-moulded cases, by contrast, use an air stream to blow the material into the mould. This process, while less common, allows for the production of more durable double-wall cases. Blow-moulded cases include Hofbauer Megabag and Quantum T, and WAG Heavy cases.
Regardless of the manufacturing process, one feature required for applying in-mould labelling is a suitable, flat area on the case’s outer surface. This is why the majority of waterproof cases, such as Peli, Nanuk, and Explorer, do not offer this (these cases typically feature ribs and contoured material to improve strength).
Benefits of in-mould labelling
Why you should consider in-mould labelling
There are a number of benefits to using in-mould labelling to brand plastic cases, including:
- Allows for high-quality graphics.
- Helps to increase brand awareness.
- Improves usability for end users.
- Designs are durable and scuff-resistant.
- The process is cost-effective (for high volumes).
- The finished product is fully recyclable.
High-quality graphics
One key benefit of using in-mould labelling is that it allows you to add full-colour, photographic-quality imagery to your cases. As the label is printed separately, you can also precisely match Pantones or other brand colours you may use.
Scuff resistant
Being moulded into the case’s body, in-mould graphics are incredibly durable. The designs will not scuff or wear over time and are unaffected by UV (so no yellowing or fading). This longevity contrasts with printed graphics, which can often become worn through regular use of your cases.
Cost-effective (high volumes)
Although not available for low-volume requirements, technological advances mean that the process is very cost-effective on high-volume runs (certainly less costly than printing hundreds or thousands of cases). It also shortens production lead times by eliminating any required printing processes.
Recyclable
Cases with labels moulded into their surface remain fully recyclable. In fact, sustainability can often be improved as the process eliminates the need for glues, adhesives, or inks, which can contaminate the recycling process. Labels used for the process are typically made from polypropylene or polystyrene.
Improved usability
In-mould labelling can improve usability for your cases’ end users (your sales teams, service engineers, or customers). It allows for adding instructions, guidance, and other important information, ensuring that any items the cases contain are used correctly and safely.
Increased brand awareness
Ultimately, in-mould labelling allows you to leverage your cases for brand awareness. This is particularly true where cases are used for added-value packaging applications where the user retains the case for storage.
In-mould-labelling-alternatives
Other options for branding plastic cases
There are a few alternatives to in-mould labelling when branding your protective cases, including:
- Screen printing.
- Digital printing.
- Printed vinyl labels.
Screen printing
Screen printing involves applying ink to a surface through a screen. The screen prevents ink from passing through certain sections, creating the design on the surface (e.g., on a protective case).
Screen printing is a relatively low-cost way to add branding and can create bold, visually appealing designs. It is also possible to print cases in low volumes.
However, it is typically limited to one or two colour designs. Designs can also become scuffed or fade over prolonged use or exposure to the elements.
Digital printing
Digital printing is similar to screen printing because it is relatively low-cost and available for low-volume requirements. Although slightly more expensive than screen printing, it does offer the potential for full-colour, photographic-quality designs, making it the closest in-mould labelling alternative.
As with screen printing, however, digital printing can become scuffed and worn over time.
Printed vinyl labels
A final option is to print full-colour designs onto vinyl labels and then apply these to your cases.
This process allows for full-colour designs and intricate, detailed graphics. It also offers the potential for changing the designs in the future (as they can simply be peeled off and new labels applied).
However, applying the labels can be difficult and, unless done well, can look messy and unprofessional. This method is also the least durable of any branding option for your cases.
Summary
In-mould labelling for cases
In-mould labelling can be an excellent way to brand any cases your business uses or sells to your customers as part of your product. It provides a high-quality, durable, long-lasting finish that can ultimately help drive brand awareness and improve the usability of your products.
However, it is not suitable for all applications, being limited to high volume requirements.
At GWP, we have supplied many cases with in-mould labelling. Working closely with case manufacturers, we can provide the full range of branding options (including printing and traditional labelling) and enhance your cases in other ways. Custom foam inserts, in particular, can significantly improve the performance of your chosen option.
As such, if you are considering a branded protective case for your business, please speak with one of our experts to see if in-mould labelling would be appropriate.
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About the author
Ian is one of the founding Directors of GWP, using his broad knowledge acquired over more than 30 years to oversee new business strategy.
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