As industrial production continues to move towards greater speed and automation, even seemingly small process variables can have a significant impact on overall performance. In-mould labelling is a clear example, where precise control of electrostatic charge can play an important role in achieving stable, efficient and repeatable production.

As modern plastics production trends toward faster cycle times and increasingly automated cells, overall process stability has become a decisive factor for competitive manufacturing. In-mould labelling (IML) represents a particularly demanding application: a pre-printed polymeric label must be picked, conveyed into the mould cavity, precisely positioned, and held securely against the metallic cavity wall before and during the high-pressure molten polymer injection phase. Under these high-speed dynamic conditions, electrostatic charging is far from a secondary operational detail; it serves as a critical technology that directly dictates process reliability, positional accuracy, and scrap-rate reduction.

In IML processes, a controlled electrostatic charge generates a temporary capacitive attraction (electrostatic pinning) between the dielectric label material and the grounded steel surface of the mould. This physical attraction ensures that the label remains tightly flat against the cavity surface, eliminating micro-movements, trapped air bubbles, and uneven adhesion caused by high-velocity material flow or mold vibrations. To maintain high-speed repeatability, the electrostatic charging system must deliver precise, pulse-free high voltage, fast response times, and seamless integration into automated robotic end-of-arm tooling (EOAT).

This specialised field is where Elettromeccanica Bonato has focused its technological development. Founded more than 40 years ago as a familyrun business in Carrè (Vicenza, Italy), the manufacturer initially engineered specialized electrostatic devices for the local textile industry. Today, the company synergizes over four decades of operational expertise with continuous R&D targeted specifically at high-demand sectors such as plastics converting, packaging, film extrusions, printing, and automated labelling.

Its engineered systems are deployed across Europe and globally within high-efficiency manufacturing facilities. To meet the demanding parameters of precise electrostatic pinning, Elettromeccanica Bonato has designed several charging generators over the years. Among these is the MINI EASY CHARGE generator, which is the perfect solution for space-critical EOAT installations and agile automated setups.

This device delivers high-precision static charging in an ultra-compact enclosure weighing just 560 grams. Operating on a 24V DC primary supply with a low power consumption of 30W, this lightweight unit produces an adjustable secondary voltage from 0 to 20 kV (with currents up to 0.8 mA) in either positive or negative polarity. Equipped with two high-voltage outputs, remote ON/OFF control, and optional snapfit splitter modules (expanding output distribution up to 8 channels), the MINI EASY CHARGE provides an ideal, decentralized solution for tight robotic end-effectors where reducing tool weight and dynamic payload is paramount.

Elettromeccanica Bonato also offers other high-performance charging generators: the EASY CHARGE series and the ECGM series. Designed for compact and versatile integration, the EASY CHARGE generator provides adjustable output voltage from 0 to 20 kV (or up to 30 kV depending on the configuration) with current output controllable from 0 to 1.0 mA. Available with positive or negative polarity upon request, the unit features an intuitive OLED display monitoring output voltage, instantaneous current draw, and operational modes. For fully automated environments, an integrated analogue remote-control interface allows PLCs or robot controllers to turn high voltage on/off instantly and adjust parameters dynamically, while up to two high-voltage outputs allow multi-point distribution.

Engineered for heavy-duty industrial applications requiring higher power margins, the ECGM-20 and ECGM- 30 supply adjustable high voltage up to 20 kV and 30 kV respectively, with current control up to 1.0 mA. Equipped with advanced overload protection, detailed fault diagnostics, and clear OLED status indication, these units ensure safe continuous operation even under aggressive cycling. Their dual high-voltage outputs and customizable polarity configurations make them highly adaptable to complex multi-cavity tools.

In an optimized IML production cell, high-voltage generators operate in tandem with dedicated application components, such as Bonato’s MCPIML charging points and specialized splitter boxes. The MCP-IML system is specifically engineered for IML tooling geometry, enabling accurate local charging of labels prior to or insertion into the mould cavity. The splitter boxes instead effectively distribute high voltage across multiple discrete charging points or custom EOAT dummy mandrels. Crucially individual output channels are fitted with decoupling resistors. This design stabilizes the ionizing charge across all contact points and actively prevents electrical arcing or dielectric breakdown between the charging emitters and the grounded metal mould.

This approach reflects a fundamental paradigm shift in modern plastics processing: static electricity should not merely be treated as an unpredictable nuisance to be neutralized or eliminated. When generated with exact parameters and controlled systematically, electrostatic charge becomes a highprecision production tool. In IML applications, targeted electrostatic pinning enhances label positioning accuracy, guarantees repeatability across multi-cavity tools, and prevents costly mold damage caused by displaced labels, ultimately providing molders with maximum uptime and superior surface finish.

For industry professionals visiting FAKUMA 2026—where advances in injection moulding machinery, industrial robotics, peripheral automation, and process optimization take center stage— electrostatic charging represents a vital link in the automation chain. Elettromeccanica Bonato’s ongoing developments demonstrate how targeted static control directly supports modern IML processing, transforming complex physical principles into stable, efficient, and highly repeatable industrial manufacturing.

elettromeccanicabonato.it

With a fully certified production system, rigorous quality control, and compliance with international standards New Rubber ensures highperformance, reliable and safe products. From custom gaskets and bellows to lasermarked components and precision-moulded parts, every solution is designed to meet the exacting demands of modern industrial applications while maintaining the highest standards of quality, safety, and efficiency.

New Rubber S.r.l. was founded in 1995 as an evolution of the original company founded in 1977 by Roberto Boriani. The company’s core business is the compression and injection moulding of technical articles, made from of all types of elastomers, solid silicone, polyurethane and Fluoroelastomer. At New Rubber, the production of technical articles and gaskets is based almost entirely based on customer drawings and specifications. All production processes are fully structured with a certified management and production system, including MOCA items, in compliance with EC Regulation 2023:2006, a fundamental requirement for food products. The company is located in Villanova di Castenaso, in the province of Bologna, and the plant covers an area of 2,800 m² and an outdoor area of over 3,000 m². The fleet of machines, completely renovated in 2024, includes presses with various features and mechanical cutting systems, for a total of 19 production plants.and the plant covers an area of 2,800 m² and an outdoor area of over 3,000 m². The fleet of machines, completely renovated in 2024, includes presses with various features and mechanical cutting systems, for a total of 19 production plants.

Service
We offer our customers with the full expertise of our technical and production departments, to support the design and specifications and define rubber products according to specific requirements. We take care of building the necessary equipment with the help of our partners. A wide range of customizable services is available, including special finishes, specific treatments, laser marking on the finished product or directly from the moulding tools, accurate visual inspections or with optical control equipment and customized packaging.

Products
Production based on customer drawings and specifications in elastomers and other special polymers.-Compact or expanded industrial gaskets made from different types of rubber depending on the use and application
.-Moulding of rubber bellows and caps
-Moulded parts in rubber, metal or plastic
-Flat industrial gaskets for mechanical cutting
-Inflatable gaskets
-Rubber gaskets and components certified for foodstuffs
-Rubber gaskets and components certified for contact with drinking water.

The products manufactured are used in a multitude of sectors and applications, including:-food production and bottling plants, -pharmaceutical production and packaging plants, -electronic components,-petrochemical industry, -electro-medical pumps and treatment of drinking and seawater -railway applications-naval and aerospace.

Processing: Thanks to the technologies we have developed, our experience and the solid support of our qualified staff, today we are able to offer the market a wide range of products, made with materials from world-leading brands. In addition, thanks to our in-house mixing department and the availability of approved industry specific compounds, we are able to respond effectively to market requirements. Gaskets and parts are manufactured by means of:
– Injection and compression moulding (including full vacuum)
– Mechanical cutting with a high-frequency blade – Custom-shaped gaskets, obtained from profiles
– Laser marking systems allow us to indelibly affix alphanumeric codes or logos to components and gaskets made of rubber or other materials

Materials: Our range of materials includes commonly used elastomers and a wide range of special polymers. Furthermore, we offer materials approved and certified according to the main international standards to ensure the safety and compliance of products intended for direct or indirect contact with food, drinking water, specific industrial applications and railway applications. Main rubbers used: NATURAL: NR – IR SYNTHETICS: EPDM – NBR – FKM, or Viton® – VMQ – CR – SBR – IRR – PU

Main reference standards for special materials:
Food contact standards:
European directive 1935/2004/EC -D.M 104 of 21/03/1973 and subsequent amendments
-Bfr Empfehlung XXI Natural and synthetic rubber-Bfr Empfehlung XV Silicone
-Arrêtè du 09/11/1994
-Arrêtè du 25/11/1992
Chinese Regulations: GB 9865-2016 GB 4806.11-2023
American Standards: FDA CFR 21 177.2600 3A
Sanitary Standards 18-03

Standards for drinking water:
-ACS France
-WRAS BS 6920-1:2000 and or 2014-KTW-BWGL

Railway Standards:
-EX UNI ISO 4189
-EX UNI 5756/66

Certifications and quality policy New Rubber srl, in addition to maintaining an active and monitored Quality system based on compliance with the UNI EN ISO 9001:2015 standard, has implemented finished product approval processes using the PPAP (Production Part Approval Process) procedure, which analyses and intervenes on all possible failure modes in the process (FMEA, Failure Mode and Effect Analysis). Moreover, for products intended for contact with food, since 2015 New Rubber srl has integrated an additional management system compliant with EC Regulation 2023:2006 (GMP, Good Manufacturing Practice) periodically reverified by the DNV certification body, a protocol necessary to ensure full compliance of the products with EC Regulation 1935:2004 (MOCA) Dimensional and quality controls Products are subjected to rigorous checks throughout all stages of the production processes, using qualitative and statistical criteria. To ensure full compliance, final checks are carried out using automatic optical inspection equipment. In addition, dimensional checks can be carried out with machine vision equipment, which allows non-contact measurements and the detection of even the smallest defects.

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​ info@newrubber.it

The activity started with Fluoropolymers has been gradually expanded with the processing of technical parts in Techno-polymers, closely developed with the customer. Fluorten S.r.l. corporate “philosophy” to work with each customer to solve project design, and production problems to obtain competitive products has continuously driven the Company to invest in people and technologies.

Currently the Fluorten S.r.l. production is composed by very modern project designing tools, extrusion and moulding process, and mechanical machining able to supply semi-finished or finished products in PTFE and injection moulded Techno-polymers with the highest Quality level. The Fluorten S.r.l. technicians guarantee an internal process with monitoring and reliability stand¬ards, that are difficult to find elsewhere.