IMDA announces winners of 2024 competition

The In-Mold Decorating Association (IMDA) has once again recognized industry leaders in in-mold labeling (IML), in-mold decorating (IMD) and in-mold electronics (IME) by announcing the winners of the 2024 IMDA Awards Competition. 

Honorees were revealed at the Plastic Product Decorating Summit on September 19 in Milwaukee, Wisconsin, with entries judged based on overall design and complexity; integration of the in-mold element into the part or package; functionality; and innovation in the use of materials and processes. Manufacturing difficulty and complexity of the part, label, design or mold also were considered.

This year, the IMDA Awards Competition received a number of entries featuring packaging and durable goods submissions that were new to in-mold – brand owners working with label printers, automation providers and molders to convert existing applications to an in-mold solution. This echoes an increasing trend toward sustainable processes and recyclable products.

The 2024 IMDA Awards Competition was possible thanks to the support Arburg, Kurz, InkWorks Printing, StackTeck, Innovia, Wipfli and Sussex IM. 

Best Label Design for IML Application
Winner: Galaxy Chocolate Milk Cup for Mars, submitted by MCC Verstraete
Product molder: Paccor
Label printer: MCC Verstraete
The judges recognized this project for its instant consumer appeal. Entering the refrigerator shelves in the Middle East, a new market for Galaxy chocolate milk, the brand wanted to go all-in in terms of shelf appeal. That's why Mars aimed at a high-quality, premium packaging with an IML label combining three label upgrades: Metallic IML (foil), Matte IML and UltraGloss IML. The result is a luxury effect that stands out from the competition.

Honorable mention: Icelandic Provisions Berry Medley Skyr for Icelanding Provisions, submitted by: Inland
Product molder: Airlite Plastics
Label printer: Inland Packaging 
Receiving honorable mention, this project from Inland was recognized because of the difficulty in applying spot color, a process not apparent to the consumer but recognized by those in the know. The original design for this product involved paperboard labels wrapped around a white tub. To enhance sustainability, Icelandic Provisions adopted IML. This also allows for more intricate and vibrant designs. The Icelandic Provision labels encompass a multitude of spot colors to showcase crisp, clean text and sharp lines. 

Best Use of IML – Traditional Aesthetic
Winner: General Mills Yoplait Greek Yogurt submitted by Inland
Product molder: Greiner Packaging
Label printer: Inland Packaging
Honored by the judges for its efforts in replacing another packaging form with an IML container, General Mills Yoplait Greek & Protein yogurt cups took a big step when making the decision to switch to in-mold labels. The judges recognized that not only was this a design change for the customer and the consumer, but also a new packaging type in an existing product line. The brand has traditionally used shrink sleeved packaging but as the markets expanded and continued to develop, they chose to switch to a more sustainable packaging type that also allowed for a higher degree of decoration. 

Honorable mention: Hiland Dairy Crema Mexicana 16 Oz, submitted by: Winpak Portion Packaging, Inc.
Product molder: Winpak
Label printer: MCC Verstraete
Automation partner: Stack Teck
The judges were excited to see this new product line launch from Hiland Dairy – Winpak’s first IML customer. This is an entire line of new IML products for the cultured dairy and dips product provider, with a total of 30 new SKUs. Hiland Dairy wanted to switch from an offset printed cup and lid to a decorated container with improved graphics. The new product line launched in January, and Winpak is now running two shifts per day, five days a week. 

Best Use of IML – Technical Achievement
Winner: Mean Girls Popcorn Bucket for GoldenLink, submitted by: Churchill Container
Product molder: Churchill Container
Label printer: General Press
The metallic label and two-sided printing caught the eyes of the judges when they saw the Mean Girls Popcorn Bucket. The typical collectible theater popcorn bucket usually features a horizontally composed version of the same poster artwork you'll find in online banner ads and outside of the movie theater. Mean Girls' unique cult following, quotability and meme-worthy content made it ripe for something totally different. Clear resin and LTZ metallic film with a limited print on the outside gives this bucket all the glitz and glam of the film, while the full color inside print carries all the meaty content superfans will eat up (once they finish their popcorn, of course). 

Honorable mention: Grillo’s Pickles, submitted by: MCC Verstraete
Product molder: Berry Global
Label printer: MCC Verstraete
The nonconventional form of Grillo's pickle container caught the eye of the judges and is enhancing the consumer experience of its packaging by introducing a leak-proof screw top. The unique sidewall design necessitated the use of IML to register the graphics with the hand grips.

Best Use of IMD for Durable Goods
Winner: ASEPT / Heinz Keystone 3.0 Dispenser, submitted by Sussex IM, Inc.
Product molder: Sussex IM, Inc.
Label printer: InkWorks, LLC
Automation partner: Sussex IM, Inc.
Molded from ABS, these dispensers stood out to the judges with their nontraditional resin and difficult production – and they made everyone wish for a hotdog from their favorite ballpark. Heinz’s Keystone Dispenser 3.0 project, initiated in 2019 with ASEPT, marks a significant advancement in dispenser technology. While the original utilized a pressure-sensitive label, the project pivoted to IML for enhanced durability and customization capabilities. The product and its decoration needed to be highly durable to withstand the high traffic and frequent use in large stadiums, fairs and similar venues. Additionally, the dispenser had to be chemical resistant to ensure thorough cleaning and sanitization with strong solutions after events. Customization is also crucial for these dispensers, representing seven different flavors of Heinz sauces.

Best Use of IMD for Consumer Products
Winner: Washer / Dryer User Interface for Electrolux, submitted by: Nissha Eimo Technologies
Product molder: Nissha Eimo
Label printer: Nissha
This entry is unique and innovative in that it's a dual UI (User Interface) for both the washing machine AND the dryer. Instead of two interfaces, this commercially successful product was able to reduce the number of UI’s, with beautiful artwork from the OEM and a UV cured hard coat on the top surface to allow it to pass a very high standard for water, bleach and chemical testing.

 
Best Use of IML / IMD for In-House Promotion or Prototype: Technical Achievement
Winner: Ultra-Thin 450 ml PET IML Food Tubs, submitted by: StackTeck Systems 
Product Molder: StackTeck Systems Ltd.
Label Printer: MCC Verstraete 
Automation Partner: StackTeck Systems Ltd.
PET! That’s all that needs to be said about this application. This mold delivers a combination of sustainable innovations such as StackTeck’s Thin Recess Injection Molding (TRIM) with a set of seven sequentially controlled valve gates to yield the lightest part of this type ever molded from PET. The IML label is manufactured from a PET substrate, achieving a 100 percent PET product. This gives brand owners, customers and consumers an alternative solution from typical PP resin-based food-grade and/or medical packaging. 

Honorable mention: Medical IML, submitted by: MCC Verstraete
Label printer: MCC Verstraete
Automation partners: ARBURG, Beck Automation, Kebo AG and Intravis
When describing what caught their eye about this entry, the judges agreed it was the precision with which the IML was applied. While IML is standard in market segments like food, it’s still rarely used in the medical sector. The Medical IML prototype centrifuge tubes were developed by five partners, and the smooth running of the process required an incredibly high level of precision for all line components and production steps.

Best Use of IML / IMD for In-House Promotion or Prototype: Design Aesthetic
Winner: Digital Soft Glow, submitted by: Kurz
Brand owner: Kurz
Product molder: Kurz
With colors that grab your attention in a pattern that is not typical for durable goods, the judges were wowed by the digital soft glow application. Printing gradients are typically very challenging. The Digital Soft Glow concept pushes the limits of the roll-to-roll printing process, delivering a beautiful and smooth color blending and gradient effect. This innovation not only enhances aesthetic appeal but also demonstrates technical expertise in achieving high-quality results that are commercially viable. 

Honorable mention: Hidden Graphic Prototypes, submitted by: Nissha USA
Brand owner: Nissha Co
Product molder: Nissha Co
Label printer: Nissha Co
The unique patterns created by Nissha USA stood out to the judges. Transmitting and displaying light is not limited to just screens and icons. By expressing various design patterns through LED transmission colors and blinking, it is possible to appeal to the user’s sensitivity. These can range from beautiful illuminations to light alarms that serve as warning signals. These decorative solutions create a seamless and comfortable space for Nissha’s customers’ products, and Nissha's submission in this category featured three new prototype patterns to showcase what is possible.

Best Use of In-Mold Electronics
Winner: Place Smart Smoke / CO Detector for Gentex Corporation, submitted by: Profile Plastics
Product molder: Profile Plastics LLC
Label printer: Duratech Industries
Automation partner: Totalmation
Judges recognized the shear difficulty of this project when awarding it as top of the category. This smoke detector decorative faceplate took over two years to get from concept to production. It requires a complex two shot mold along with two appliques. The first applique is for decoration, and the second is for the circuits providing lighting as well as a capacitive touch sensor. A flex tail was also molded into the part and is used to interface with the smoke detector circuit board. RGB LEDs are utilized that allow for
infinite colors to be displayed from the smoke detector. The final molded part allows for a sleek design without physical buttons while maintaining a very thin part profile. Given that this unit is for the consumer market for residential use, the aesthetics are extremely important, especially given the significant competition already on the shelves. 

Honorable mention: Overhead Light Console for Prototype, submitted by: Kurz
Product molder: Syntech
IMD decoration: Leonhard Kurz
Sensor label: PolylC
Automation partner: Wittmann
Both functional and aesthetic, the judges appreciated the Overhead Light Console (OHLC), which is a prototype for an overhead control unit in automotive interior. It consists of a seamless surface which is decorated by single picture IMD process. It contains transparent areas for reading light, for touch-control-buttons, for a touch-control slider, for ambient light backlighting and a hole for an optical projector. The design is a day-night design with hidden-til-lit areas for the backlighted control buttons, the slider and the ambient light areas. In the control button area, the surface also has 3D patterns to guide the finger by finding the right button. The decoration is protected with a UV top coat for high quality protection of the surface according to automotive specifications. On the backside, a capacitive touch sensor is integrated by in-mold electronics (IME). 

Sustainable Use of In-Mold Processes
Winner: Mirage Reusable Container for Richardson Food & Ingredients, submitted by: MCC Verstraete
Product molder: Fourmark
Label printer: MCC Verstraete
The judges appreciated the different thinking that occurred in relation to the package and the use of IML to create a dual-purpose container, addressing both current market trends and the reusability conversation with a removable IML. In a market segment where disposable containers set the tone, Mirage offers its 907 g margarine in a reusable container. The brand chose to create an environmentally friendly, mono-material packaging that is durable, reusable, dishwasher and microwave safe. To achieve this, they opted for Peelable IML, a label that consumers can easily peel from the packaging, leaving them with a container which can be reused as a freezer container or storage box. 

Honorable mention: IML-Decorated Spice Container for Jesus Navarro S.A., submitted by: MCC Verstraete
Product molder: ITC Packaging S.L.U.
Label printer: MCC Verstraete
Judges always appreciate the replacement of a non-sustainable packaging type, and in this case, the packaging switched from a metal container to a monomaterial IML packaging in a cubed shape for stackability. Thanks to the new packaging, the weight of the packaging and the raw material needed to manufacture it were reduced by 66 percent. In addition, logistics were optimized as the amount of packaging that can be transported in a lorry was increased by 80 percent. 

Honorable Mention: Milram 185 g Thermoformed IML Container for DMK Group, submitted by: MCC Verstraete
Product molder: Pöppelmann GmbH & Co. KG
Label printer: MCC Korsini
Honorable mention was awarded for this container due to its lightweighting through the use of IML-T. The original packaging consisted of a plastic container decorated with glued-on paper label. Now, Milram’s packaging is the first in its segment offered in Thermoforming IML packaging, unique in the German market. The new packaging saves up to 30% packaging material - this corresponds to around 200 tonnes of packaging material per year. 

Judges’ Choice Award
Winner: Cooler Boxes, submitted by Ren-Flex Packaging South Africa 
Product molder: PENFLEX
Label printer: REN-FLEX Packaging, South Africa
The judges applauded this family of products differentiated by IML and using resin colors to unify the designs. The effect created instant appeal from across the room – a giant IML with impact! RenFlex has manufactured over 100 different designs for the cooler boxes with digitally printed labels on a 760 mm x 1100 mm web. The IML label with the transparent lamination will not deteriorate during outdoor use or allow the ink to be scratched off, creating a cooler box that will be used for years to come.

Honorable mention: Color-Gradient Decorating Shell with IME Functionality, submitted by IMR Technology Co., Ltd.
Product molder: IMR Technology Co.
Label printer: NIS Co.
Automation partner: IMR Technology Co.
The judges chose to recognize this part, very simply, because it combined functionality and aesthetic appeal, combining IMR/lME injection molding with touch light and pressure sensor functions. The design of the part includes a variety of surface designs, including gravure printing and NCVM vacuum coating technology, which gives the surface a metallic appearance. The design allows the product to be colorful, while the matching electronic component includes interesting light transmission and functional effects.