By Dianna Brodine, vice president, editorial, Plastics Decorating
What started as a demo at K 2025 turned into a mainstream hit when iPB Printing introduced its durable cold foil IML
reusable cup.
Roots in the food industry
iPB Printing was founded as a family-owned business in 1938 in the Netherlands. Originally active in the food industry, the growing importance of packaging led to the company starting to print its own packaging in 1991 and, soon after, the labels of its suppliers. Eventually, the import and export business in biscuits and confectionery was sold, printing activities were expanded and the company’s core business focus permanently shifted.
Eighty-eight years later, the printing company for in-mold labels and flexible packaging has grown into an international player, serving major brand names such as Coca-Cola, Disney, Budweiser and McDonald’s. Still, the company maintains its roots as a family business, with brothers Bart and Ton Lavrijsen serving as owners and directors.
The Rockstar Cup was developed by iPB Printing as a demonstrator application to showcase the possibilities of durable cold foil in-mold labeling (IML) for reusable plastic drinkware. The primary production goal was to combine high-impact visual decoration with long-term durability, advanced functionality and sustainability. During its introduction at K 2025 in Düsseldorf, it generated strong interest from brand owners, molders and packaging professionals and quickly became a conversation starter around premium decoration, reuse and smart packaging concepts.
The cups were produced by Churchill Container (Lenexa, Kansas), a partner of iPB Printing, using recycled polypropylene supplied by PureCycle (Orlando, Florida). While the Rockstar Cup itself was produced as a limited demo series, the underlying durable cold foil IML concept has since been adopted in commercial production projects for multiple customers worldwide.
Producing a hit
The Rockstar Cup features an in-mold label with cold foil elements that create a high-gloss metallic effect suitable for the rock music characters who come to life in the design. A protective laminate coating adds scratch resistance and long-term durability. IML was chosen because it allows decoration, protection and functionality to be integrated directly into the injection molding process. The label becomes an integral part of the product surface, resulting in a durable, scratch-resistant finish suitable for repeated washing and intensive use.
IML also enables a mono-material construction, with both the cup and label made from polypropylene, allowing full recyclability without adhesives or secondary components. From a functional perspective, IML makes it possible to integrate invisible codes and double-sided printing without affecting the exterior design. This combination of aesthetics, durability and smart functionality cannot be achieved with post-mold decorating techniques.
Design and effects
The design process started with defining a bold, collectible visual identity inspired by rock music and stage aesthetics. The goal was to transform a functional reusable cup into a desirable object that people want to keep and reuse. Graphic design, foil placement and data integration were developed in parallel.
The illustrated rockstar characters featured on the label are inspired by members of iPB Printing’s own team. This personal and playful approach proved highly effective when the cups were handed directly to prospects during trade fairs.
In addition, the label incorporates an invisible code with variable data so that each cup can be uniquely identified and linked to promotional campaigns, return and deposit systems, reuse tracking or logistics processes, making it especially relevant for the event and hospitality sectors. Special attention was given to ensuring that functional elements, such as codes and informational layers, would not interfere with the visual impact of the artwork.
The label also includes printing on the inner side of the IML, acting as an additional information carrier. This inner print can be used for technical data, instructions, traceability or lifecycle information, while keeping the outside of the cup visually clean.
The label was produced with transparent polypropylene-based IML films, selected for their dimensional stability, heat resistance and compatibility with cold foil application, lamination and injection molding. Printing was carried out using 10-color UV HD flexographic presses, enabling high-resolution graphics, dense ink coverage and precise registration of cold foil elements.
Cold foil and invisible codes are both sensitive to process conditions, so extensive testing and optimization were required to ensure that foil integrity, code readability and print quality were maintained throughout injection molding. This involved fine-tuning material selection, adhesive systems, laminate structures, press settings and molding parameters.
Sustainable influence
iPB Printing is actively committed to sustainability, with its efforts focused on reducing waste, optimizing production processes and creating a positive work environment for its employees. It only makes sense that the company would pay close attention to the development of sustainable packaging solutions. iPB’s laminated labels, for example, are ideal for reusable products, such as drink cups. Additionally, the company always is looking for ‘mono-materials’ so that the final product, including its packaging, can be recycled together.
These priorities were center stage in the development of the Rockstar Cup, which was molded from recycled polypropylene supplied by PureCycle. The use of PureCycle PureFive™ rPP was a key element in achieving the sustainability objectives of the project.
Designed for long-term reuse, the Rockstar Cup aims to significantly reduce the environmental impact of “single-use” drinkware by creating a product that avoids the trashcan. Laminated IML ensures the decoration remains intact after dozens of wash cycles and, thanks to the mono-material PP construction, the cup and label can be recycled together without separation when use is complete. By combining strong visual appeal with smart, invisible functionality, the design encourages reuse while enabling efficient return, tracking and reuse systems.
Artistic achievement, commercial success
Although the Rockstar Cup was developed as a demonstrator, it has been showcased extensively at international trade fairs, including K 2025 in Düsseldorf, customer presentations and industry events. Its combination of premium aesthetics, durability, recyclability, invisible coding and inner-label information layers also earned the cup recognition in the 2025 IMDA Awards Competition, where it won Best Use of IML in a Small Container.
The concept has since been translated into commercial production projects for multiple customers worldwide, especially within the event, hospitality and reusable packaging sectors, and ensuring its status as a powerhouse on the global stage.