This article takes an in-depth look at labeling machinery.
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Labels are an important aspect of product packaging, identification, presentation, and traceability. They are a way of communicating the manufacturer to the customers and the rest of the world. Labels promote the brand of the product and indicate the product information needed to know by consumers. Labels also facilitate the traceability and tracking of products in the supply chain.This article will look at the different labeling machinery and systems.
Labeling machinery refers to any equipment involved printing and attaching labels to the products.
Labeling machinery has a wide variety of applications since most commercial products have attached labels on the actual item and its packaging. They can also create labels on cartons, cases, and pallets. The industries served by these machines are food and beverage, pharmaceutical, agriculture, home and office, electronics, agriculture, and much more. The applications of labeling machines are diverse and plentiful. Labeling machines can create texts and graphics as simple barcodes, 2D codes, batch code, and expiration dates to vivid images and logos.
Labeling machines are categorized based on the function they are intended to perform in the labeling process – printing, dispensing, and attaching. Typical labeling machinery has a combination of these types of machines.
There are two levels of labeling machinery automation:
In the succeeding chapters, we will discuss the different labeling machines.
Printing is the first step in any labeling process. In this step, the design of a label is reproduced on the substrates or films. The substrates can be made of plastic, paper, and metal foils. The printed labels are cut from the web of the substrate then bonded to the product. An adhesive film is present on each printed label's backside to attach them effectively to the product or packaging.
The types of printing machines used in labeling systems are as follows:
Inkjet printers have numerous nozzles which spray microscopic ink droplets onto the substrate to create an image. These printers can create high-quality, complex, and vibrant colored images, texts, and graphics. They can blend and produce colors better than laser printers. Inkjet printer ink is also compatible with a variety of substrates which include plastic films, textured art paper, and glossy photo paper. These printers have a low initial cost, but the price of the consumable ink remains a concern.
To create the desired image, laser printers melt the toner and dry powdered ink onto a substrate. Next, laser beams form the selected image on a rotating drum capable of carrying an electrostatic charge on its surface. The negatively-charged toner particles will adhere to the charged image on the drum. Next, the toner particles are transferred and fused by heat and pressure onto the substrate. Finally, the leftover ink and electrical charges are cleaned in preparation for the next printing cycle.
Laser printers can create multi-colored images, texts, and graphics quickly. Laser-printed images are durable; they can withstand UV light exposure, heat, and rubbing. Unlike ink, you can store toners for months without drying them since they are made from powdered plastic materials. Laser printers are economical in the long run. However, the variety of substrates compatible with laser printing is fewer than inkjet printers.
RFID labels, or smart labels, are the most common type of passive RFID tag which stores information (e.g., serial numbers) and transmits data to a reader. They consist of a label material embedded with an RFID interlay or chip. They do not have an internal power source; instead, they are powered by the electromagnetic energy transmitted from an RFID reader. RFID is widely used in supply chain management to track the flow of materials and products and monitor inventory levels in a factory, warehouse, or any facility.
RFID label printers perform several tasks. First, they write and encode the data in each RFID chip. The printer then verifies if the input data is encoded correctly. Finally, the RFID label printer will print the label showing the additional texts and graphics related to the product. RFID label printers are available in industrial, desktop, and mobile models with different configurations to cater to various labeling applications.
Thermal printing is the most common method of label printing. Thermal printers work by activating the heating elements from the printer head, producing the substrate image. They are commonly used in retail and grocery stores, the shipping industry, and banking. They make images quickly at a low price. There are two types of thermal printers:
Direct thermal printers rely on the Leuco dye chemistry of the thermochromic film, which changes its color as it is being heated by the printer heated. The image produced is usually a monochrome (e.g., black-and-white image), but a two-colored image may be made by heating the film at two different temperatures.
Direct thermal printers do not use ink, toner, or ribbon. However, the print can fade when rubbed or exposed to sunlight, UV light, direct heat, and vapors. These printers are used in printing receipts and shipping labels.
Thermal transfer printers transfer solid ink from a ribbon onto a substrate. The transfer is initiated by heating the ink from the ribbon using the printer head. The images produced by these printers last longer than those images printed by a direct thermal printer, provided that the ink has sufficient affinity to the substrate. The substrate available for thermal transfer printing is made paper, acetate, vinyl, polyester, and nylon.
Label applicators, also known as label dispensers, are labeling machines that attach pre-printed labels on films, with pressure-sensitive adhesive (PSA) on their backside, to products, containers, cases, and packages. The labels are attached to the products while being transported by a conveyor.
Proper alignment of the products is ensured before the attachment of the labels. First, a roll of loaded pre-printed labels is unwound. Next, the liner on the backside of each label is removed to expose the PSA. The labels are then separated from the web. The “peeled label” is held by the labeling head on the opposite side of the PSA. When the machine senses a product, the product will pause in front of the applicator, and then the labeling head will stick the PSA under the label to the product. Once the label has been attached, the product will travel along the conveyor and proceed to the succeeding processes.
Label applicators provide efficient and accurate labeling solutions. They are suitable for labeling high volumes of products. They can flexibly apply labels on the top, bottom, sides, and corners of the product.
The following are the types of label applicators based on the method of dispensing the labels:
Air-blow label applicators generate a vacuum to hold the label on the head before applying it to the product. When the machine senses the product, compressed air is blown by the pneumatic solenoid valve, causing the PSA of the label to stick on the product. Air-blow label applicators are best for fragile and odd-shaped products.
Tamp-blow label applicators are also non-contact applicators, like air-blow applicators. They also utilize the negative pressure created by a vacuum to hold the label before applying it to the product. These applicators use a pneumatic cylinder that moves the label toward the product, increasing the accuracy and consistency of the label placement. Compressed air is blasted to apply the label on the product. Hence, the label is used without the labeling head touching the product. Tamp-blow applicators are ideal for attaching labels to uneven surfaces.
Wipe-on label applicators are the most common type of label applicators. These label applicators utilize a roller that applies the label on the product passing through the applicator. The movement of the product and label must be synchronized to avoid wrinkling of the labels. When the conveyor stops moving, the operation of the label applicator should also be paused. Wipe-on label applicators ensure bubble-free labeling. In addition, the operating cost is much lower than non-contact applicators since wipe-on applicators do not utilize compressed air.
Tamp label applicators rely on the positive tamp action to force the label against the product's surface. This creates a seal between the label and the product. They are good at applying labels on rugged surfaces. Tabletop sizes and manually-operated versions of these applicators are available in the market.
The products are aligned on the conveyor to ensure accurate and consistent label placement. The machine unwinds the web of substrate wherein the desired image is printed. When the device senses a product, the product will pause in front of the applicator, and then the labeler will attach the newly printed label. Once the label has been secured, the product will travel along the conveyor and proceed to the succeeding processes. The machine will print a new label for the following product sensed. The movement of the conveyor and the attachment of the label are synchronized. The products are gapped as they travel along the conveyor to give the machine ample time for printing and tamping.
Print and apply labelers also increase efficiency and reduce human error and labor costs, which can help you meet high volume demands and quality requirements. Unlike pre-printed label dispensers, you can easily make changes to the design and content of the image to be printed without even wasting any material. They can be used in encoding variable information about the product such as lot batch numbers, expiration dates, and barcodes.
Depending on the machine's configuration, print and apply labelers can also attach labels on the top, bottom, sides, and corners of the product or packaging. Then, they dispense the printed labels by air-blow, tamp, blow-tamp, and wipe-on methods as described earlier.
Labeling systems are integrated assemblies of various label applicators, dispensers, printers, and material handling equipment. They are used in labeling processes that are fast-paced and require a high level of precision and consistency. The following are the types of labeling systems:
Front-back labeling systems apply seamless labels on the front, back, and sides of the product. In these systems, two labeling heads are positioned face-to-face. As the conveyor brings the product to the labeling heads, the labels will be simultaneously attached to the front and back sides of the product. The label is wrapped for rounded products by passing the product through a series of rollers. The movement of the product and the preparation of the label is precisely timed to ensure accurate label application.
Front and back labeling systems are ideal in applying labels to flat and rounded containers.
Top and bottom labeling systems apply labels at the top and bottom surfaces or only the top or bottom surface of the product. In these systems, the labeling heads are positioned at the top and bottom of the product. The roller rotates and applies the labels as the product passes through the labeling heads. The movement of the product and the conveyor and the preparation and movement of the label is precisely synchronized.
Top and bottom labeling systems are suitable for applying labels on tub style and clamshell containers, boxes, cartons, and cases. They are compatible with all types of packaging, including shrink or bubble-wrapped products.
Wrap-around labeling systems apply labels to the lateral surfaces of cylindrical containers such as cans, bottles, cartridges, and canisters. Wrap-around labeling is used to utilize the large surface area as efficiently as possible. The label is wrapped fully or partially around the lateral surface of the container as the product is made to spin and pass through the labeling head.
A vial labeling system is a wrap-around labeling system dedicated to attaching labels to vials. Vials are small, cylindrical glass bottles primarily used in the pharmaceutical industry and contain liquid or powdered medications, vaccines, and specimens. They are also used in other industries to contain fragrances, oils, chemicals, flavorings, concentrates, etc. Pharmaceutical labels are strictly regulated and usually have a lot of information about the product. Wrap-around labeling is used for the vial labeling system to maximize the lateral surface area of the vial so that wide labels can be attached. These systems are not limited to the pharmaceutical industry and can label any sensitive products contained in vials.
In rotary labeling systems, the products are transported from a linear direction to around a continuously rotating circular base called the carousel. Individual platforms have circulated the carrousel onto which each product is placed and held in position by a top clamp. The platform rotates on its axis accordingly as it approaches the applicator to present the proper side of the product wherein the label is to be applied. The label is often wiped down; the product is spun around its axis as it passes through a stationary wiper to wrap the label around the product. If multiple labels on the products are desired, the platform again rotates to present the other side of the product to the applicator for the following labeling process.
Rotary labeling systems require a high level of synchronization between each machine component. They are commonly used in high-speed labeling flat and rounded bottles, containers, and vials.
Semi-automatic labeling systems are initiated by an operator or a device to label arranged or lined up products. The complexity of semi-automatic labeling systems varies from hand-loaded applicators for start-ups and small production volumes to integrated into a production line. The production rates of these labeling systems differ depending on the level of automation. Semi-automatic labeling systems are used for businesses that streamline their labeling process.
Labeling machinery is handy in the case of packing and aggregation. Aggregation is the process of serializing products and their components during production and distribution based on a parent-child relationship among packaging levels. The image below shows the mapping of aggregation. As you can see, the individual packs are the “child” of the bundle pack (“parent”), and this relationship continues as the products move up to a higher aggregation.
A vision system scans the serialization of each child. Once the machine has recorded all the serial numbers, the items making up the aggregate will be bundled and given a unique serial number. Labeling machinery is needed to print and apply the serial number label.
Aggregation is widely employed in the pharmaceutical industry, though it is also practiced in the food and cosmetic industry. Each product is easily tracked and monitored through this practice by the supply chain participants. It can also fasten damaged pallets' decommission and efficiently process product recalls and returns.
Labeling systems with washdown enclosures are suitable for harsh environments. The labeling machinery is housed in a stainless steel enclosure and protected during a washdown.
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