Smart In-Mold Labelling with Comau Racer-5 Robots

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Flexible Side-Entry IML Automation for Packaging Lines

Fast, precise, and seamlessly integrated, this in-mold labelling (IML) solution combines two Comau Racer-5-0.63 robots with linear axes under a single controller.

The result? A high-speed, fully synchronized automation cell tailored to consumer goods production.

Integrated IML Automation with Comau Robotics

This video highlights a compact, high-efficiency IML solution using Comau’s Racer-5-0.63 robots.

Thanks to seamless integration with linear axes and a single B&R controller, the system offers unmatched flexibility and operational ease:

  • Fast side-entry IML with two synchronized robots
  • One control panel for all robot and axis adjustments
  • Quick reprogramming for new products in less than 30 minutes

Case Study: Streamlined IML with Comau Racer-5

In this system, two Comau Racer-5-0.63 robots handle high-speed label application inside molds, synchronized with 4 linear axes. The result is a plug-and-play IML automation concept that simplifies changeover and maximizes efficiency:

  • Modular structure adaptable to various mold types and product sizes
  • One control panel for full system operation
  • Automated repositioning of axes and robots when switching products
  • Dual access doors for maximum operator accessibility

How the Comau IML Automation Works

All-in-One Control

The entire robotic and axis system is managed via a B&R controller, eliminating the need for multiple interfaces and enabling real-time adjustments with just one mobile panel.

Flexible Side-Entry with Dual Robots

Two Comau Racer-5 robots perform synchronized label placements with high speed and repeatability, ensuring smooth and efficient operation on both fixed and movable sides of the mold.

Quick Changeovers

Switching product formats is effortless: operators simply select a new recipe, and the system automatically adjusts robots and axes to the new specifications in under 30 minutes.

Why Choose Comau for Packaging Automation?

Integrated Robotics for Smart Factories

Comau’s robots are engineered for seamless integration with the software and control systems you already use, supporting faster commissioning and streamlined workflows.

Compact Robots for High-Speed Applications

The Racer-5-0.63 delivers high speed and precision in a compact footprint, making it ideal for side-entry IML and fast pick-and-place applications in tight spaces.

Plug & Play Flexibility

Full system control from a single panel allows for quick reconfigurations, reduced training time, and increased productivity—all from one intuitive interface.

Ready for Digital Manufacturing

As part of Comau’s Integrated Robotics ecosystem, this solution supports advanced digitalization, real-time monitoring, and high-performance automation tailored to your production needs.

About the System Integrator: HAGENSTADT

Hagenstadt engineers, constructs and installs machines that support optimal automation of your production lines. Available options vary from machines with an adjustable side-entry and modular systems up to machines and systems that are entirely tailor-made such as assembly, part inspection, stacking, IML, Storage systems.

Based on its professional production analysis, Hagenstadt develops machines that focus on user-friendliness, valueing a close cooperation with the project leader, in order to prevent any disruptions to the production line.