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How can you achieve a good labeling job?

How you can achieve
a good label application with pressure sensitive labels.

In order to achieve successful labeling one must start by analyzing
the entire line and eliminating where any bottle necks may occur. The labeler
is not necessarily the most important factor for success although certain speeds
and consistency’s must be assumed. Most labelers in a similar price range
will perform the duties required. Differences in brands however will determine
ease of use and reliability.

The main challenge for consistency is proper and repeatable placement of the
product. If placement can not be guaranteed then label accuracy can not be guaranteed
regardless of the quality of labeler.

Products may vary in size and shape from bottle to bottle as
well in consistency of material. Bottles have weak spots or differ in outside
diameter. Boxes are formed differently. Stretch film over wrap packages such
as fruit or mushrooms have different shapes from package to package; all significant
challenges to successful labeling. In an ideal world your labeler
will be manufactured and assembled with your product in mind. If a generic labeler
is being used then separate product handling devices are essential.

Buying a labeler
and then trying to figure out how to put your products through is not an ideal
plan for success. Picking a labeler that is universal may seem effective in
the beginning but invariably trying to do too much with too little gives poor
results.

Cost

Speed, accuracy and versatility are all determining factors in the costs of
labeling equipment. Each extra control device adds to the complexity of the
engineering and in some cases the operations of the equipment.

It is important to understand your minimum and maximum wish list for the performance
of the labeler. Try
where possible to select all product containers prior to selecting the labeler.
Set production levels that are realistic to your actual throughput needs, keeping
in mind that you can only produce to the maximum speed of your slowest production
machine. Labeling at 100 bpm when your filler is only capable of 60 bpm will
not provide satisfactory results. Additionally select equipment that will meet
your numbers while performing at 85% of its maximum speeds.

What about accuracy?

Ideally we expect to achieve 100% accuracy with our labeling equipment. Due
to many factors, some listed above, this is not realistic. Determine your acceptable
tolerances, speeds and then start your search for a labeler. 99% accuracy is
achievable but there are inherent costs involved and no reasonable short cuts.

Product Handling Components

When applying a wrap around label to a round container you will need to separate
the products to allow for the trailing edge of the label to have room to wrap
in the wrap station. Bottles which travel too close will attach themselves to
this trailing edge. A rule of thumb for spacing is to space equal to the length
of label to be applied. Rectangular or square cases will require spacing in
order to get a reset on the product sensor. In most other cases there will be
allowance for automatic reset due to the product shape.

Spacing for slower speed lines can be achieved with low cost
metering rollers or indexing gates. Such devices momentarily stop the product
and release it with controllable delay. This works at up to 60 products per
minute on empty and faster on full containers however this can be limited due
to the weight of the product as it builds up behind the gates. Faster speeds
require a metering or timing screw which are custom made to one product size.

Centering Chains or Belts are used to put a product into the
middle of the conveyor and to align the products in identical fashion. This
component is most effective when used in conjunction with a hold down conveyor.

Hold Down Conveyor: As the name says, it holds down the product,
sandwiching the product between it and the transport bottom conveyor. This ensures
the reliable presentation of the aligned product to the labeler.

Conveyors can be the most important component of labeling. At
the same time it is also the most ignored. Most labeling equipment is supplied
with 1” to 1 ½” links and the bigger the links the rougher
the chain runs producing more bounce in the product. With longer conveyors the
effect can be spread with little harmful effects but they can become extreme
for short, 6’ or under, conveyors. Often, label applicators are placed
on existing lines where conveyor bounce, motor irregularities and drive problems
are an issue that may cause the products to sway or alter their positioning
during labeling.

If you label dry products
and are not as concerned about spills, try not to use chain conveyors at all.
There are a number of different belts available for different frictions and
smooth product conveyance.