IML Dummy Cores
DETAY ROBOTIK is specialized in the design and production of IML Dummy Cores, also known as "IML Dummy" or "IML Mandril." IML Dummy Cores can be described as the functional key part located at the very end of the IML Robot. To explain further, the IML Label taken from the IML Magazine is wrapped around the IML Dummy with the help of the vacuum. It is then transferred to the mold by means of the IML Robot. While the dummy core is inside the mold, the static charger is activated generating static electricity. The static electricity and the blowing channels on the dummy help the IML label adhere correctly inside the mold. The Injection Process is then carried out so that the IML Container is manufactured. After product removal, the item is transferred either by free fall or product stacking mechanism. With this technology, various IML Containers used in many different sectors are manufactured. Within this context, many different plastic containers and cups in the food industry - such as yoghurt cups, ice cream containers, food containers can be mentioned. The labels embedded in plastic containers produced by the IML Method cannot be removed by hand, and also the image quality is very high. Therefore, IML Containers are particularly preferred by prestigious producers who value brand impression.
The IML Dummy plays a critical role in this process, since the vacuum and blowing grooves on the IML Dummy Core (IML Mandrill) must function synchronously. Most importantly, the IML Dummy Core must adequately perform the static charging function. We produce the following types of dummy cores according to the shape, size, and operating conditions of IML Containers: Resin Type Dummy Cores, Pin Type Dummy Cores, Foam Type Dummy Cores, and 3D Printed Dummy Cores. Having separate vacuum and blowing lines ensures more efficient operation. Nevertheless, it is also possible to operate them on the same line if required. We can produce IML Dummy Cores in volumes ranging from 0,20 liters to 1 liter, 2 liters, 4 liters, 8 liters, 10 liters, and 20 liters. Similarly, we have produced dummy cores ranging from 1 cavity to 16 cavities. Thanks to its high performance, our IML Dummy Cores have gained the appreciation of our customers in both local and international markets and have become a preferred product.
RESIN TYPE DUMMY CORES
Resin Type Dummy Core is one of the most preferantial types of dummy cores. In Resin Type Dummy Cores, static electricity transfer from the Dummy Core to Label is effected through "resin" . Resin is a special gel-like semiconductor material that is poured into channels of Dummy Core. Those Channels & Dummy Core body is machined on precision CNC Machines. Resin should be poured carefully so that the intrusion of air is prevented in order to avoid leakages. After solidifying, final processing is conducted on CNC machines for obtaining the final shape. Resin ensures excellent static electricity transfer due to its semiconductor properties and allows for a wide area of static electricity transfer. Therefore, it yields very good results, especially in larger mandrels (10 liters - 20 liters) where a wider area of static electricity transfer is required. Typically, the bodies of our standard Resin Type mandrels are made from PP (Polypropylene) material. Our Resin Type mandrels have gained customer satisfaction in both local and international markets and have become a preferred IML product by IML Container&Lids manufacturers.
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PIN TYPE DUMMY CORES
Pin Type IML Dummy Cores are designed so that the static charging is effected through special alloy needles. The high voltage from the static charger is transferred to the IML label by means of the tips of these pins (needles). This results in a highly effective transfer of static electricity. Our Wired Pin System is a special product developed by our engineers as a result of the Government&University supported R&D Studies. Static electricity is transmitted with very high efficiency from the tips of the pins. We can produce the wired pin system in various configurations, such as sets of 4, 6, or 8 pins. We can place the desired number of wired pins on the IML dummy. This ensures high-efficiency performance. The pin type performs particularly well in IML container forms in which static charging is difficult and under high humidity conditions. High humidity makes the transfer of static electricity challenging, but pin-type dummies perform well in such environments. Additionally, the IML (In-Mould Labeling) Pin Systems that we are producing are removable and can be easily replaced in case of need. Along with all our Dummy Cores, we also provide an IML distributor. These Distributors include resistant and protect the dummy, mold, and injection machine against possible short circuits. This also ensures the safety of the operator. Our Pin Type dummy cores provide the highest level of static charging. They have become a preferred product in the local and international markets. This is especially due to their highly effective performance in medium-sized containers such as 1-liter, 2-liter, and 5-liter capacities. Our Pin Type Dummy Cores have received the satisfaction of our valued customers.
3D-PRINTED DUMMY CORES
3D-Printed Dummy Cores are especially preferred by customers who wishes to operate with very high efficiency. The bodies of our standard cores are made from PP (Polypropylene) material. Although PP material is lightweight, in some cases, there is need for an even lighter body. Especially when the payload capacity of the IML Robot is low, it is necessary to reduce the weight of the dummy core and IML accessories. This is the reason why 3D Printed Dummy Cores are preferred by customers. Dummy Core made from 3D-Print material is around 50% lighter than PP material. On the other hand the cost of 3D Print Dummt Cores is a bit higher. This advantage of having lightweight is an effective and efficient solution for specific IML Productions in which the payload capacity of robot is critical. Accordingly, due to the reduced load on the robot arm, the IML Robot can operate faster and more efficiently. 3D-Print Cores are preferred for complex-shaped forms and large dummy cores. As company, we use the lightest materials in all our dummy cores and we make the most optimal designs in our 3D-Print Dummy Cores. Particularly, IML Container manufacturers who prioritize mass-production and aim for high-tech production prefer our 3D-Printed Dummy Cores.
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LID DUMMY CORES
Lid Dummy Cores are manufactured as Foam Type. Since the Lid surface is flat, a special type of polymer material that we call as " Foam" gives very good results. This material is a semi-conductive material that shows high performance in the transmission of static electricity over flat surfaces. Our Lid Type Mandrils can be supported with auxilliary pins when needed. Thereby, in cases where static electricity is not sufficient, additional measures and applications are carried out by us. Foam Material is used in all IML applications where the surfaces are flat. For example, foam material is also used for IML applications over plastic tables. Although the material we call "Foam" is a simple component, it provides a very effective static transmission. Our Foam Type Dummy Core is a very solution-based product and has already earned the satisfaction of our customers operating in In-Mould Labeling sector in both local and foreign markets.
DETAY Pinning System
DETAY Pinning System is a special product developed by our technical engineers with the support of University & Government. These Pins are made from a special alloy, enabling very high-efficiency static electricity transfer. Our Wired Pin System is produced in configurations of 1, 2, 4, 6, 8 pins, and customized pin numbers upon request. In case of inconvenience with pin type dummy cores, the wired pin system can be used as a replacable spare part. Additionally, with the resistant distributor (distributor) - we provide with all our dummy cores- the dummy core, mold and IML Robot are protected against potential short circuits. Our Pinning System is a technological product that meets international standards and can be used as a performance product by our customers in both local and foreign markets.
