At K 2025 in Düsseldorf, Netstal, Hall 15, booth D24, will present a high-efficiency system solution for producing 1-liter in-mold labeled pails. The exhibit centers on the Elios 5500 PAC, a machine variant optimized for packaging with a clamping force of 5500 kN. The setup emphasizes high precision, stable process consistency and leading energy efficiency to support maximum productivity and part quality. IML pails for yoghurt and other dairy products in the 1-liter class are widely used, and this packaging format combines a high-quality appearance with improved recyclability, high material efficiency and a lower CO2 footprint compared with alternative materials. Netstal has been active in IML since its early days and has continuously focused on packaging efficiency, defined as the ability of packaging to fulfill its functions while minimizing material use, costs and environmental impact.
The running application exemplifies thin-wall production with reduced material consumption. It leverages high injection dynamics to reliably fill thin flow paths at short cycle times, and integrates automation for label placement, part take-out, inspection and stacking. The complete cell combines the machine, mold, IML labels and peripherals to illustrate consistent production of lightweight, recyclable pails.
Thin-wall IML pail application
The 1-liter pail is molded in polypropylene supplied by material partner Sabic and weighs 23 grams. According to internally documented reference applications, around 20 years ago each pail required approximately 15 grams more material. Achieving such a low part weight at thin walls demands high injection performance. Netstal’s Elios series, a benchmark for thin-wall packaging since its 2016 launch, provides the required dynamics. On the Elios 5500 PAC, the hybrid injection unit with two-valve technology delivers injection speeds up to 1100 mm/s in High Power mode and a maximum injection pressure of 2400 bar. The high-precision RFC injection control, with control resolution in the millisecond range, maintains part weight within tight tolerances.
The 1-liter yoghurt pail weighs just 23 grams
System configuration and automation
Production runs in a 4-cavity mold from system partner Brink. Brink also supplies an integrated side-entry handling system. The high-speed automation inserts the labels into the cavities, removes finished parts, performs camera-based inspection and stacks the pails on a conveyor. The NextCycle IML labels from partner MCC Global are optimized for recycling and approved by the Recyclass organization. In mechanical recycling, the PP label completely detaches from the container and therefore does not affect the polypropylene value stream.
Clamping performance and energy efficiency
The cycle time is 3.8 seconds, corresponding to around 3800 parts per hour. The clamping unit uses a robust 5-point double toggle lever for dynamic yet mold-protective movements under high loads. The dry cycle time of the 5500 kN machine is 1.7 seconds. With a tie bar distance of 920 mm by 920 mm and an opening stroke of 901 mm, the Elios 5500 PAC accommodates larger molds without difficulty.
The hybrid drive concept features energy recuperation. Kinetic energy generated during braking is fed into the main drive’s electric motor, converted into hydraulic energy and stored. Even under full load, this enables up to 50 percent electricity savings compared with a fully hydraulic machine. An optional system pressure reduction can further increase energy efficiency without reducing productivity. This option permanently adjusts the maximum hydraulic system pressure to an optimal level, lowering energy use and mechanical load. The benefit depends on the gap between the machine’s maximum system pressure and the actual pressure required by the application.
Powerful and energy-efficient: The Elios 5500 PAC produces a thin-walled IML pails at K 2025
Controls, connectivity and peripherals
The Axos 9 control system supports intuitive operation of the fully integrated cell, enabling users to exploit the machine’s performance potential. The optional four-button Smart Operation feature simplifies and safeguards routine machine control in production environments. Digital services include the free Netstal eService and the fee-based Netstal Remote Control. For standardized data exchange and integration, current machines are equipped with Euromap interfaces based on OPC-UA. Digital partner bfa solutions will demonstrate efficient integration by connecting both injection molding machines on the Netstal booth to its MES solution.
Peripherals on the exhibit include a material feeder from Piovan and a chiller from ef cooling, rounding out the cell configuration for continuous, high-throughput thin-wall IML production.
