Combining modularity, flexibility and performance.

Does high performance in IML production necessarily mean giving up flexibility? Are advanced manufacturing cells reserved only for side‑entry robots? Our latest project shows that you can have all three: speed, versatility and cost optimisation.

Here is a case study in which the modular approach of MATSIM – Automation & Robotics, combined with technology from Wittmann Battenfeld Polska Sp. z o.o. and Sumitomo (SHI) Demag, gives new meaning to performance and flexibility.

Efficient integration — the key to success

As MATSIM, we were responsible for the full integration of the production cell. Our task was to build a system that makes optimal use of the potential of the following components:

• Hybrid El‑Exis injection moulding machine from Sumitomo (SHI) Demag.
• Ultra‑fast Cartesian robot Wittmann Sonic.
• Modern four‑cavity mould for producing 200‑ml containers with cross‑label IML.

To achieve this, we used our own modular IML‑automation components.

Premium performance: a 6.2‑second cycle

Thanks to perfect synchronisation between the high dynamics of the Sonic robot and the trademark speed of the El‑Exis, we achieved a total cycle time of 6.2 seconds. The process includes applying the IML labels, removing finished parts and stacking them precisely.

This result is competitive with many applications using side‑entry robots — reached with a lower cell complexity and significantly reduced investment costs.

MATSIM modularity — the foundation of flexibility

At the heart of our solution lies a modular automation concept. Components such as the label magazine, IML inserts, gripper and the stacking module were designed to be quick and easy to swap, enabling swift changeovers.

From the production‑planning perspective, this brings measurable benefits:

• Minimised changeover times between different products,
• Maximum utilisation of the cell,
• Higher availability and profitability of the machines.

Safety and scalability

The system is complemented by an optimised safety concept adapted to the compact layout and compliant with the requirements of the Machinery Directive. The modular architecture also allows easy expansion, for example with visual inspection or connectivity to ERP/MES systems.

Project specification

Robot: Wittmann Sonic (Cartesian)

• Injection moulding machine: El‑Exis, Sumitomo (SHI) Demag
• Product: rectangular 200‑ml container
• Number of cavities: 4
• Technology: IML (cross‑label)
• Total cycle time: 6.2 s

MATSIM responsibilities

• Selection and technical specification of all third‑party cell components (Wittmann, Sumitomo (SHI) Demag).
• Design and build of modular IML components: IML label magazine, mould inserts, gripper, stacker, safety system.
• End‑to‑end integration into a fully operating production cell, plus CE certification.

A solution for demanding manufacturers

The modular IML cell is our answer for producers who expect not only performance but also the ability to adapt quickly to changing market needs. Would you like to know how we can increase the efficiency of your production? Contact us — the MATSIM team will be happy to analyse your needs and propose a tailored solution.