Edited by Dianna Brodine, vice president, editorial, Plastics Decorating
For sports fans, there’s nothing better than when the leaves begin to change and the stadiums fill to overflowing. From Major League Baseball’s postseason play to football’s weekly match-ups, volleyball matches and soccer games, eager supporters of high school, college and professional athletic teams, gather to cheer on their favorites.
One necessity when all those fans come together? Food! And, thanks to Wisconsin-based injection molder Sussex IM, the condiment dispensers for all that ballpark food look better than ever.
Condiment dispensers level up
Since 1977, Sussex IM is a proven, long-standing leader in mid- to high-volume (100,000+) custom molding. With two facilities totaling more than 280,000 square feet, Sussex IM boasts molding machines ranging from 25 to 725 tons. The company specializes in highly complex parts, utilizing automation and post-molding capabilities to service markets as varied as consumer products, agriscience/garden, medical/pharma, residential durable and industrial.
In 2019, Sussex IM began working with ASEPT for the design of the Keystone 3.0 for ASEPT’s partner, Kraft Heinz. The ASEPT Group is a portfolio of companies that work together to provide specialized dispensing solutions to a range of industries worldwide, including food service, personal care, sanitation and more.
While the original condiment dispenser design utilized a pressure-sensitive label, the project pivoted to Sussex IM’s innovative idea for an in-mold labeling (IML) solution for enhanced durability and customization capabilities. However, the COVID-19 pandemic in March 2020 necessitated a delay in the project until the reopening of restaurants and stadiums, key markets for Heinz. Throughout 2021 and 2022, design and development efforts continued, culminating in early 2023 with collaborative design work involving ASEPT, Sussex IM and Inkworks LLC. “We are grateful for the partnership with Sussex IM and knew we could trust them with the implementation of the in-mold labeling technology,” said John Rayburn, representative of ASEPT.
By September 2023, the finalized designs were set into motion with the launch of tooling and automation processes. Key features of the Heinz Keystone 3.0 dispenser include an ABS substrate and large, satin-finish in-mold labels on two sides, as well as a prominently displayed front panel IML with a matching satin finish. The dispenser labels utilize multiple colors representing seven different flavors of Heinz sauces, including ketchup, mustard, mayo, ranch, relish, barbecue and honey mustard.
IML adds necessary durability, custom look
According to the team at Sussex IM, the Heinz dispenser was the ideal candidate for in-mold labeling technology. The product and its decoration needed to be highly durable to withstand the high traffic and frequent use in large stadiums, fairs and similar venues. Additionally, the dispenser had to be chemical resistant to ensure thorough cleaning and sanitization with strong solutions after events. Unlike adhesive labels that would wear out under such conditions, in-mold labels provided the necessary durability.
“The Heinz IMLs are laminated in-mold label structures that encapsulate the inks under a top layer of polypropylene for easy cleaning and sanitizing,” said Jim Naatz, business development director for Sussex IM. “The inks cannot be scratched off or wash away over time. The base layer of the in-mold label is a co-polyester (coPET) that fuses to ABS plastic.”
Naatz continued, “Multiple textures were trialed as part of the development process. Although the housing surface finish is more of a polished look, Heinz landed on a satin look for the IML. This was beneficial in many ways. One, the satin finish of the IML provided a softer, richer look to the IML that Heinz really liked. Two, because of the size and clarity requirement of the IML, the satin finish helped mask any potential imperfections or contamination that may be trapped between the IML and substrate.”
Customization also was crucial for these dispensers, as they are used at large events where swift decoration changes are essential. “The digital printing of IMLs allows for highly-detailed graphics, and our in-house automation team can place these labels within the magazine system to be run in the same production run without disruption,” Naatz said. “The printing was done on an HP Indigo press, so the digital imagery can change as customers’ needs change or if they require targeted customization without the cost of plates or additional set-up costs.”
Overcoming production challenges
According to Naatz, the Heinz Keystone 3.0 housing is molded on a 500-ton Krauss Maffei press, and the production process presented several challenges. First, to achieve an even flow front, the gate had to be optimally located to ensure proper flow around the large in-mold labels, preventing ripples in the labels. Sussex IM’s engineers conducted multiple mold flow simulations to determine the best gate location and flow front. Additionally, the cooling of the mold was crucial to the molding process.
Second, the large size of the labels, which cover three sides of the dispenser, required precise placement to prevent shifting during molding. Automation for picking and placing the IMLs for this dispenser was much larger than typically designed and came in two different sizes.
“The large size of the labels and high static made it difficult for the vacuum system to pick up the labels effectively,” said Naatz. “However, our in-house automation team successfully developed a system that could pick up all three labels and place them into the mold without shifting.”
The automation system, built at Sussex IM, consisted of a magazine system that fixtures the individual labels in a nest and presents it to the end-of-arm tooling and robot. The end-of-arm tooling and robot pick up the three labels, static charges the labels and places them into the cavity of the mold.
The crowd goes wild
The Heinz Keystone 3.0 dispenser received enthusiastic feedback at the National Restaurant Show show in May. Its customizable options and sophisticated, classic look generated interest among US markets and particularly captured the attention of international markets. In September 2024, the dispenser was awarded, “Best Use of IMD for Durable Goods” in the In-Mold Decorating Association’s Awards Competition.
In a fun twist, attendees of IMDA’s Plastic Product Decorating Summit in September were invited to attend a Milwaukee Brewers baseball game as a pre-event networking opportunity… and the Heinz Keystone 3.0 dispensers were found near hotdog stands throughout the stadium. Go, team!
