Summaries of IMDA Case Studies


The new packaging format for National Foods' 1kg Yoplait tub, launched in supermarkets Australia-wide in October 2006, has delivered the kind of leap in on-shelf differentiation rarely seen in a market as small as Australia's. 

Replacing the thermoformed HIPS container typical of high volume dairy brands across Australia, Yoplait's move to a robust injection moulded tub with photo-quality in-mould labelling, unique on-pack tamper evidence and custom designed grip and pouring features has undoubtedly raised the bar in chilled dairy packaging across Australia.

The redesign had been on the agenda for several years but market research indicated a complete overhaul of the current tub was required to address the weaknesses inherent in thermoformed packaging. The challenge for National Foods was what and how to do this with minimal impact on the shelf footprint.

Injection moulding technology has been standard fare in the European dairy case for the past two decades but Australia's lower volumes and costly barriers to entry meant, until now, thermoformed HIPS was the only locally-made packaging option for large volume Australian FMCG chilled dairy brands. Recognising the potential for injection moulding technology in Australia, VIP Packaging (formerly Visy Industrial Packaging), one of the country's leading packaging providers, had been working on developing the right combination of tooling, robotics and labelling for some time in order to produce a product on par with leading European IML manufacturers.

National Foods' need and VIP's IP came together at the right time, culminating in an innovative and highly successful new packaging format for the well-known yoghurt brand.


Polisport, a manufacturer of polypropylene panels and parts for off-road motorcycles, wanted to improve the appearance and durability of their products. These dirt bike panels are subjected to a lot of mechanical stress and abuse from heat and gravel during competition.

Polisport's experience with pressure sensitive labels was unsatisfactory in terms of placement, durability and esthetics.

After much experimentation with various materials and working with several partners in the in-mold decoration value chain, Polisport developed an in-mold decoration process that not only provids dirt bike decoration with superior durability, but also greatly enhanced appearance and reduced costs.


Reddotnet, Inc., a manufacturer of electronic purchasing kiosks used in high traffic retail environments, needed to improve the overall durability and cosmetic look of their display panel bezel used by a national retail chain.

Paper pressure sensitive labels originally used to decorate the bezel face peeled, frayed and wore out quickly, resulting in frequent replacement and increased costs.

Manufacturing design was changed to allow use of in-mold decoration with film labels. These in-mold labels do not peel, fray, wear off, discolor or scratch under high traffic conditions in retail sites.


Redbox revolutionized the entertainment industry ten years ago by democratizing access to movies with a simple, yet effective, business model: Give consumers convenient access to the hottest new releases at an incredible value. The injection molded cases that hold the DVDs, Blu-ray Discs, and video games need to hold up well over many uses while promoting the Redbox brand.

Originally, during the startup days of Redbox, the cases were pad printed. However, the company experienced a lot of degradation of the inks due to repeated handling of the cases. As its success grew, Redbox wanted to improve its image through the cases that the customers saw at the point of purchase.

The results of the collaborative efforts of Redbox, Evco Plastics and CBW Automation working together as a team, which is key to developing a high-speed, high-tech IML system, the results met the group’s expectations.

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