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 encompasses all types of equipment designed to print and affix labels onto products.
These machines have extensive applications, as nearly all commercial products feature labels on both the items themselves and their packaging. Labeling machinery can also be utilized for labeling cartons, cases, and pallets. They serve various industries including food and beverage, pharmaceuticals, agriculture, home and office supplies, electronics, and more. Labeling machines are versatile, capable of producing everything from basic barcodes, 2D codes, batch numbers, and expiration dates to complex images and logos.
Labeling machines are classified according to their role in the labeling process, which includes printing, dispensing, and applying labels. Most labeling systems integrate several of these functions into a single machine.
Labeling machinery can be automated at two different levels:
In the upcoming sections, we will explore various types of labeling equipment.
The initial phase in labeling involves printing. During this phase, the label design is transferred onto various materials, such as plastics, papers, and metal foils. After printing, the labels are cut from the material and applied to the product. Each label has an adhesive layer on the back to ensure a secure attachment to the product or its packaging.
Different types of printing machines are utilized in labeling systems, including the following:
Inkjet printers operate with multiple nozzles that release tiny droplets of ink onto the substrate to form images. They are capable of producing detailed, high-resolution images, texts, and graphics with rich, vibrant colors. Compared to laser printers, inkjet printers offer superior color blending and are compatible with a wide range of materials, including plastic films, textured papers, and glossy photo papers. While these printers are initially affordable, the ongoing cost of ink cartridges can be a significant factor to consider.
Laser printers produce images by melting toner, a powdered ink, onto a substrate. This process involves using laser beams to project the image onto a rotating drum with an electrostatic charge. The toner particles, which are negatively charged, adhere to the charged areas on the drum. These particles are then transferred and fused onto the substrate using heat and pressure. After printing, any residual toner and electrical charges are removed to prepare the drum for the next job.
Laser printers are capable of quickly producing high-quality, multi-colored images, text, and graphics. The prints are durable and resistant to UV light, heat, and abrasion. Unlike liquid ink, toner, being a powdered substance, does not dry out and can be stored for extended periods. Although laser printers offer long-term cost savings, they have fewer substrate options compared to inkjet printers.
RFID labels, also known as smart labels, are a prevalent type of passive RFID tag used for storing and transmitting information, such as serial numbers, to an RFID reader. These labels are made from a label material that contains an embedded RFID chip or interlay. Lacking an internal power source, they rely on electromagnetic energy from the RFID reader for operation. RFID technology is extensively used in supply chain management for tracking materials and products, as well as for monitoring inventory in factories, warehouses, and other facilities.
RFID label printers have multiple functions. They write and encode data onto each RFID chip, verify that the data has been accurately encoded, and then print the label with additional text and graphics related to the product. These printers come in various models, including industrial, desktop, and mobile versions, each designed to meet specific labeling needs.
Thermal printing is a widely used technique for label production. Thermal printers operate by heating elements in the printer head to create an image on the substrate. This method is frequently employed in retail and grocery settings, as well as in shipping and banking sectors. Thermal printers are known for their speed and cost-effectiveness. There are two primary types of thermal printers:
Direct thermal printers utilize a thermochromic film with Leuco dye chemistry that changes color when heated by the printer's heating elements. Typically, this process produces monochrome images (such as black-and-white), though a two-color image can be achieved by applying different temperatures to the film.
These printers operate without the need for ink, toner, or ribbons. However, the printed images may be prone to fading when exposed to friction, sunlight, UV light, direct heat, or vapors. Direct thermal printers are commonly used for printing receipts and shipping labels.
Thermal transfer printers work by transferring solid ink from a ribbon to a substrate. This process is triggered by heating the ink with the printer head. The resulting images from thermal transfer printers tend to be more durable compared to those produced by direct thermal printers, as long as the ink adheres well to the substrate. Thermal transfer printing can be used on a variety of materials, including 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.
To ensure proper label placement, products must be aligned correctly before labels are applied. The process begins with unwinding a roll of pre-printed labels. The backing liner of each label is then peeled away to expose the pressure-sensitive adhesive (PSA). The labels are separated from the backing web, and the "peeled label" is held by the labeling head, which positions it on the side opposite the PSA. As the machine detects a product, it pauses the product in front of the applicator, allowing the labeling head to apply the PSA to the product. Once the label is affixed, the product continues along the conveyor to subsequent stages of processing.
Label applicators offer precise and efficient labeling solutions, ideal for handling large volumes of products. They are versatile, capable of applying labels to various surfaces, including the top, bottom, sides, and corners of products.
Here are the different types of label applicators categorized by their label dispensing methods:
Air-blow label applicators use a vacuum to hold the label in place on the applicator head before application. When the machine detects the product, compressed air is released via a pneumatic solenoid valve, causing the pressure-sensitive adhesive (PSA) to adhere to the product. These applicators are particularly well-suited for delicate or irregularly shaped items.
Tamp-blow label applicators are another type of non-contact applicator, similar to air-blow applicators. They use vacuum pressure to hold the label before it's applied to the product. A pneumatic cylinder moves the label toward the product, enhancing the accuracy and consistency of label placement. Compressed air is then used to apply the label, ensuring that the labeling head does not touch the product. Tamp-blow applicators are particularly effective for labeling uneven or irregular surfaces.
Wipe-on label applicators are among the most widely used types. They use a roller mechanism to apply the label onto the product as it moves through the applicator. To prevent label wrinkling, the movement of the product and the label must be precisely synchronized. If the conveyor stops, the applicator should also halt to ensure proper label application. Wipe-on label applicators are effective at providing bubble-free labeling and are more cost-efficient compared to non-contact applicators, as they do not require compressed air.
Tamp label applicators use a positive tamping action to press the label onto the product's surface, creating a secure seal. They are particularly effective for labeling rough or uneven surfaces. These applicators are available in various sizes, including tabletop models and manually-operated versions.
Print and apply labelers are machines designed to print and attach labels directly onto products and packaging as they move along a conveyor. These devices combine the functions of printing and dispensing into a single unit. The label is printed on-site and immediately applied to the product, streamlining the labeling process.
Products are aligned on the conveyor to ensure precise and consistent label application. The machine unwinds a roll of substrate with the desired image to be printed. When the system detects a product, it pauses in front of the applicator, which then applies the freshly printed label. After the label is affixed, the product continues along the conveyor to the next stage of processing. The machine immediately prepares a new label for the next product. The conveyor movement and label application are carefully synchronized, with products spaced appropriately to allow the machine enough time for printing and labeling.
Print and apply labelers enhance efficiency and reduce the risk of human error and labor costs, making them ideal for meeting high-volume and quality standards. Unlike pre-printed label dispensers, these systems allow for easy adjustments to label design and content without wasting materials. They are also capable of encoding variable information such as batch numbers, expiration dates, and barcodes.
Depending on their configuration, print and apply labelers can apply labels to various locations on the product or packaging, including the top, bottom, sides, and corners. They utilize methods such as air-blow, tamp, blow-tamp, and wipe-on to dispense the printed labels.
Labeling systems consist of integrated assemblies that combine different label applicators, dispensers, printers, and material handling equipment. These systems are designed for high-speed labeling processes that demand precision and consistency. The following types of labeling systems are available:
Front-back labeling systems apply labels to the front, back, and sides of a product. These systems feature two labeling heads positioned opposite each other. As the product moves along the conveyor, the labels are simultaneously applied to the front and back. For rounded products, the label is wrapped around by guiding the product through a series of rollers. The synchronization of the product's movement and label preparation ensures precise application.
Front-back labeling systems are well-suited for labeling both flat and cylindrical containers.
Top and bottom labeling systems apply labels to the top and bottom surfaces of a product, or exclusively to either surface. In these systems, labeling heads are positioned above and below the product. As the product moves through the system, rollers rotate to apply the labels to the desired surfaces. The synchronization of the product's movement, the conveyor, and the label application process is meticulously managed to ensure accurate labeling.
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 are designed to apply labels to the side surfaces of cylindrical containers, including cans, bottles, cartridges, and canisters. This method maximizes the use of the container's surface area. As the product rotates and moves through the labeling head, the label is wrapped fully or partially around the container's lateral surface.
A vial labeling system is a specialized wrap-around labeling system designed for applying labels to vials. Vials, which are small, cylindrical glass containers, are commonly used in the pharmaceutical industry for storing liquid or powdered medications, vaccines, and specimens. They are also utilized in other sectors for products like fragrances, oils, chemicals, flavorings, and concentrates. Pharmaceutical labels are subject to stringent regulations and often contain extensive product information. The wrap-around method is employed in vial labeling systems to efficiently use the vial's lateral surface, allowing for the attachment of larger labels. While these systems are particularly valuable in the pharmaceutical field, they are also suitable for labeling other sensitive products 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 necessitate precise synchronization among all machine components. These systems are often employed for high-speed labeling of both flat and cylindrical bottles, containers, and vials.
Semi-automatic labeling systems are activated by an operator or a device to label products that are arranged or aligned. These systems range in complexity, from simple hand-loaded applicators suitable for small production runs to more sophisticated models integrated into production lines. The production rates of semi-automatic labeling systems vary based on their level of automation. They are ideal for businesses looking to streamline their labeling processes while accommodating different production volumes.
Labeling machinery plays a crucial role in packing and aggregation. Aggregation involves serializing products and their components during production and distribution, based on a hierarchical parent-child relationship among packaging levels. The image below illustrates this aggregation mapping. As depicted, individual packs are considered the "children" of the bundle pack, which acts as the "parent." This hierarchical relationship extends as products move up through higher levels of aggregation.
A vision system scans the serial numbers of each individual item. Once the machine has recorded all serial numbers, the items are grouped together and assigned a unique serial number for the aggregate. Labeling machinery is essential for printing and applying this serial number label.
Aggregation is commonly used in the pharmaceutical industry, as well as in the food and cosmetics sectors. This practice facilitates easy tracking and monitoring of products throughout the supply chain. Additionally, it speeds up the decommissioning of damaged pallets and streamlines the process for product recalls and returns.
Labeling systems with washdown enclosures are designed for harsh environments. These systems are housed in stainless steel enclosures that provide protection during washdown procedures, ensuring durability and longevity in challenging conditions.
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