The Austrian plastic box manufacturer and pool operator STECO INTERNATIONAL POOL LOGISTICS has been working on the utilization of RFID technology in reusable container pool systems for some time, primarily seeking to improve the precision and efficiency of controlling its own pool system. A made-to-measure identification and tracking solution now achieves this objective. After an extensive process and requirements analysis, Schreiner LogiData developed a special Inmold-Identlabel that combines barcode and RFID technologies, thus making all key data available in various forms. The label is incorporated into the plastic box during the production process by means of injection-molding technology and is subsequently protected from external influences by a solid plastic coating. Equipped with the ((rfid))-Inmold-Label, the boxes are much easier to control, which optimizes the logistics process chain across the entire pool system.

Every day, several million returnable boxes and containers are moved and distributed across Germany. The complexity of controlling such a reusable packaging pool system increases with the number of parties using the system, the system’s scope and the number of transactions that need to be performed. Efforts to heighten the transparency of and to improve the controlling process for such systems have been under way for some time, and RFID technology is a key factor in achieving these objectives.

Some reusable shipping containers have traditionally been equipped with transponders, either in the form of hard tags (transponders firmly cast into ABS or PU housings) or in the form of conventional, self-adhesive smart labels. However, the disadvantage of these solutions is that the tag is not an integral component of the tagged item. Particularly where durability or compliance with external form factors is required, the suitability of these solutions is limited.

For this reason, Schreiner LogiData in conjunction with Schreiner Group has been working on the development of inmoldable ((rfid))- and Code-Labels for a number of years, seeking to integrate the transponder during the production process of an injection-molded plastic component. Inmold decoration technology provides the advantage of firmly embedding the label into an object such as a plastic crate. Compared to adhesive ((rfid))-Labels, inmolded labels exhibit a significantly higher resistance to handling and cleaning processes.

In terms of compliance with hygienic regulations in food and pharma logistics the (rfid))-Inmold-Label offers a number of advantages over the adhesive version as well. In addition, the in-process integration of RFID technology eliminates the need for subsequent, often cost-intensive, labeling and practically creates a “counterfeit-proof RFID infrastructure“ at the beginning of the process and supply chain.

However, embedding a tag into an object such as a reusable container by means of inmold decoration makes special demands on the identification medium – not only with regard to the selection of appropriate materials. A standard ((rfid))-Label would not have a permanent chance of surviving the processes to which it is typically subjected.

But the road toward an “intelligent“ injection-molded component with RFID technology that possesses the requisite resistances is long. The manufacturing process itself represents a major challenge when integrating an ((rfid))-Inmold-Label into another object, as the permanent bonding with the injection-molded component requires a special material composition, which must be adapted to temperatures and other specific aspects of the production process.

In addition, to ensure the transponder functionality, an antenna design must be selected that will deliver reliable service in rough day-to-day operations even after having suffered thermally induced in-process shrinking during production. Consequently, quality is the number one priority, not only before but also during the manufacturing process. The transponder has to meet numerous challenging service requirements: During its five-year warranty period neither mechanical, chemical nor thermal loads may impair its performance. In addition, the transponder’s presence must not degrade the stability and functionality of the tagged object, such as its stackability and load bearing capacity.

These aspects illustrate the complexity and large number of requirements associated with inmolding of RFID technology. Last but not least, there is no such thing as a “typical“ manufacturing process for injection-molded parts. As a general rule, the materials, antenna design, injection mold and label composition must be adapted to the customer’s specific requirements, and viable solutions are achieved through the joint efforts of injection molders, mold-makers, pool operators, users of returnable containers and label developers.

For further information:

Schreiner Group GmbH & Co. KG
Competence Center LogiData
Bruckmannring 22
85764 Oberschleißheim
Tel.: +49 89 31584-4140
Fax: +49 89 31584-4109
rfid@schreiner-logidata.de
www.schreiner-logidata.de