Competitor and Market Analysis: Collect case studies of IML applications for similar products; analyze the target market’s requirements for label appearance and durability.

Preliminary Mold Flow Analysis: Use mold flow analysis software to simulate the filling, holding pressure, and cooling processes; verify whether plastic flow in the label area is uniform to prevent label curling.

Label-Substrate Compatibility Testing: Test the hot-melt bond strength between the label and the plastic melt; verify whether the label will shrink or discolor under high temperature and pressure.

Preliminary Equipment Selection Plan: Determine the required injection molding machine tonnage and injection speed (high-speed machines recommended); preliminarily select the robot type (side-entry or top-entry); plan the basic configuration of the automated post-processing line (stacking, packaging).

Detailed Mold Design: Design the layout of cavities, cores, and cooling channels; design label positioning structures (vacuum ports, electrostatic adhesion slots); design mold collision and scratch prevention structures.

Label and Printing Design: Finalize the label artwork and determine the imposition layout; select the printing process (gravure, flexography, digital printing); produce sample labels and conduct on-press testing.

Automation Solution Design: Design the label magazine, as well as the travel range and gripping method for the label-picking robot; design an integrated solution for product removal, conveying, stacking, and packaging; plan the control system architecture for the entire production line (PLC, HMI, MES interfaces).

Auxiliary Equipment Selection and Procurement List: List specifications for dehumidifying dryers, chillers, mold temperature controllers, air compressors, etc.; determine the models for conveyor belts, counting devices, and packaging machines.

Project Schedule and Budget Preparation: Establish milestones for mold manufacturing, equipment procurement, and assembly/commissioning; prepare a detailed budget, including provisions for trial production and contingency costs.

Mold Manufacturing and Trial Molding: Machining, heat treatment, and polishing of mold components; conducting T0 trial molding at the mold factory to inspect label placement and molding results; mold optimization and maintenance (e.g., adjusting suction holes, adding venting).

Label and Printed Material Production: Bulk printing, die-cutting, and inspection of labels; anti-static and dust-proof treatment for label packaging.

Injection Molding Machine and Auxiliary Equipment Procurement/Manufacturing: Procurement or manufacturing of high-speed injection molding machines (e.g., hybrid hydraulic-electric machines); procurement of dehumidifying dryers, chillers, etc., and completion of factory testing.

Automation System Integration: Assembly of robots, label magazines, conveyor belts, and stackers; wiring of control systems and preliminary program debugging.

On-site Pre-assembly and Integrated Testing of the Complete Line: Assembling all modules into a production line at Keming or the supplier’s facility; conducting dry-run tests to verify timing synchronization.

Equipment Positioning and Leveling: Position the injection molding machine, robotic arm, conveyor belt, and other equipment according to the layout diagram; adjust the leveling and install vibration-damping pads.

Water, Electricity, and Air Line Connections: Connect the cooling water, compressed air, power supply, and signal lines; check the air line seals and voltage stability.

Safety Device Inspection: Verify the functionality of safety doors, light curtains, and emergency stop buttons; check the safety interlocks between the robotic arm and the injection molding machine.

Individual Equipment Functional Testing: Perform an idle run of the injection molding machine (mold opening/closing, ejection, injection unit); test the movement of each robot axis and label retrieval from the label magazine; ensure auxiliary equipment (dryer, mold temperature controller) reaches set values.

Full-Line Idle Cycle Integration Testing: Without a mold in place, simulate the process of label retrieval → mold opening → label placement → mold closing → part retrieval → conveying; adjust the timing of each action and optimize the cycle time.

Mold and Label Setup: Install the IML mold and connect the vacuum/static generator; load standard labels and test the accuracy of the adhesion position.

Process Parameter Tuning: Set the barrel temperature, mold temperature, injection speed, and holding pressure; optimize cooling time and balance the molding cycle.

Small-batch trial production: Continuously produce 100–500 molds, record the yield rate; inspect label positioning, fusion quality, and product dimensions.

Performance metric verification: Measure product weight, wall thickness, and label adhesion; test whether the line’s cycle time meets the designed capacity; verify that the scrap rate is below the agreed-upon threshold (e.g., <1%).

Continuous operation testing of the automation system: Run continuously for 24 hours and record the number of shutdowns; verify the accuracy of stacking and packaging counts.

Signing of the acceptance report: Compile test data and have both parties confirm compliance with requirements; develop a corrective action plan for outstanding issues; sign the provisional or final acceptance form.

Site Survey and Preliminary Preparation: Verify the workshop floor’s load-bearing capacity, ceiling height, and logistics pathways; identify locations for cooling water, power, and compressed air connections.

Equipment Hoisting and Unpacking: Arrange for a crane and forklift to move the equipment to the installation site; remove packaging and inspect the exterior and spare parts.

Leveling and Securing: Use a spirit level to adjust the equipment’s level; secure with anchor bolts or install vibration-damping pads.

Preliminary Connections: Connect the main power supply and control cables; connect cooling water lines and air hoses.

Site Cleanup and Signage: Clean up installation debris and post safety and operating signs.

Operational Training: Train customer operators (injection molding machines, robotic arms, and automation interface operation); train process engineers (parameter adjustment, mold maintenance, and label replacement); train maintenance technicians (troubleshooting common issues and replacing wear-and-tear parts).

Process Documentation and SOP Delivery: Provide Standard Operating Procedures (SOPs); provide mold maintenance guidelines and label storage requirements; provide electrical schematics and pneumatic diagrams for the entire production line.

Remote and On-site Technical Support: Establish a 24/7 remote support hotline; conduct regular on-site inspections (e.g., quarterly); respond to emergency faults within 4 hours and arrive on-site within 24 hours.

Spare Parts Supply and Maintenance Agreement: Provide a list of wear-and-tear parts and recommended stock levels; sign an annual maintenance contract that includes preventive maintenance; system software upgrades and feature enhancements.

Continuous Optimization and Data Iteration: Collect customer production data to optimize molds or processes; provide modular retrofit solutions based on new product requirements; conduct regular follow-ups to gather suggestions for improvement.