In-Mold Label (IML) Flexo Consultant

Objectives of the assignment​

1. Assess Skanem Africa’s current IML capabilities (people, process, equipment, substrates, customers).

2. Design and implement a robust, documented, and repeatable IML production workflow for UV flexo from raw material to finished stack.

3. Reduce waste and trial costs during IML start-up and customer approvals.

4. Develop in-house competency through operator, prepress and QA training.

5. Create customer confidence by aligning to best-practice test methods and performance criteria for IML labels.

Scope of work

The scope will cover narrow-web UV flexo IML for injection and blow moulding (70–120 µ PP films, or as agreed).

Diagnostic & gap analysis

• Review current:

o IML customer portfolio and specifications

o Substrates, inks, varnishes, plates, aniloxes

o Press configuration & curing system

o Schober / rotary die-cutting set-up

o Existing SOPs, QC checks, and test methods (peel, scuff, adhesion, distortion, etc.)

• Run on-press observation of at least 1–2 IML jobs to map actual practice.

• Provide a gap analysis vs world-class IML standards (storage, corona levels, ink laydown, registration, curl control, etc.)

Process & workflow design

• Define standard IML production flow from order entry to shipment, including hand-offs between Sales, Prepress, Production and QA.

• Recommend and document:

o Substrate handling and conditioning (humidity, temperature, storage time)

o Corona treatment targets and verification routines

o Ink / varnish systems and curing windows

o Plate / anilox selection, impression control, anti-static measures

o Registration and tension set-up specific to IML films

o Schober/die cutting parameters (web tension, cutting pressure, anti-static, matrix removal, stack control).

• Propose press set-up standards (e.g. target densities, viscosities, speeds, UV mJ/cm², etc.) per IML product family.

SOPs, documentation & “Golden Rules”

• Draft or refine Standard Operating Procedures (SOPs) for:

o Substrate receipt, QC and storage

o IML job make-ready & changeover on flexo presses

o In-process quality checks (visual, functional, dimensional)

o Schober/die cutting and packing of IML stacks

o Handling, palletisation and shipping to moulders.

• Create simple one-page “IML Golden Rules” posters for:

o Press operators

o Die-cutting/finishing operators

o Warehouse & logistics

• Recommend basic IML test methods aligned with recognised industry guidance (e.g. surface tension tests, adhesion checks, scuff resistance).Plastics Decorating

Trials, optimisation & customer approvals

• Support planning and execution of:

o Internal production trials to stabilise the process

o Selected customer moulding trials with key accounts.

• Fine-tune parameters based on moulding results (label insertion behaviour, fusion, shrink/distortion, colour stability).

• Define a standard approval protocol (sample quantities, test plan, acceptance criteria, documentation).

Training & capability building

• Deliver structured training for:

o Press operators and assistants

o Prepress/graphics team

o QA/technical team

o Sales/Key Account Managers (high-level “how to sell IML” and what makes it different).

• Provide training materials that Skanem can reuse internally (slides, checklists, troubleshooting guides).

Key deliverables

1. Diagnostic report with gap analysis and prioritised recommendations.

2. Documented end-to-end IML UV flexo workflow, including flowchart.

3. SOP pack (Word/PDF) for all key stages listed in 3.3.

4. IML Golden Rules posters (operator-friendly one-pagers).

5. Standard press set-up sheets and QC checklists for typical IML SKUs.

6. Trial & approval report template for customer IML projects.

7. Training sessions (on-site and/or virtual) plus training materials.

8. Final handover report summarising improvements, KPIs and next steps.