Labeling Machine Inquiry or Order Process
The following article going over the assessment of labels and bottles for a given Labeling Machine inquiry or order.
With this level of knowledge applied to a client inquiry, you can confidently move forward with both machine and label supply.
The consistency of products is entirely out of our control and we can only guarantee solutions where the product meets specifications and is accurately represented by the samples we have assessed to be suitable for the job.
1.0 Moving to Product Labeling Automation – Conveying to the Client why we need samples
When people are moving away from hand labeling to Automated or Semi-Automated labeling they are entering into a new level of production with new constraints. During hand labeling, the operators have a chance to make corrections for product variations, packaging variations and label variations. They have the advantage of tactile dexterity and vision. An exaggerated example of this can be found in our video discussion of “Taking On This Cookie”.
Disclaimer: This is a case study for discussion purposes only. No claim is made as to the supply of equipment or the endorsement by any of the parties or products contained or seen in this video”
With Automated labeling, we need to orientate the product, detect the product and wipe or wrap a label onto the moving surface of the product.
2.0 Sources of Variation in Products
Variations in products, the labels and the operator set-up will all statistically add in an automated labeling process to present a worst case label application scenario. The labeling machine also has minor tolerances of operation that will also add to the worst case scenario.
2.1 Products variation
THE MORE SAMPLES YOU COLLECT THE MORE TRUE THE PICTURE YOU HAVE AS TO CURRENT PRODUCT VARIATIONS.
2.1.1 Product Size
Variations in product size are invariable; even for Plastic or glass containers.
A product that is say 200mm tall can easily have a height variation of .5% or 1mm
This information is often available from the packaging supplier as a Tolerance.
2.1.2 Product Shape
When a product varies in shape this presents the worst kind of variation for Automation and indeed for hand labeling.
Labeling with self-adhesive labels requires that that the label is applied to a surface that is flat OR has a curve in ONLY one direction.
With round bottles the curve is in the direction of the Circumference. In some instances the manufacturers of round containers do not carefully control the shape of their containers and you see variations in the walls of the round bottles which results in complex contours (A surface with a curve in more than one direction).
See the full article: “Complex Contours on Round Products”.
2.2 Label Variation
While the die shape of a label may be fixed and invariable, its position on the web will vary:
The label manufacturer should be able to advise of the slitting tolerance of the web they can achieve; this can often be +/- 0.5 or 1.0 mm.
These slitting tolerances lead to label position tolerance as the label head that dispenses the labels is fixed in position.
2.3 Operator Setting Variation
A skilful operator is still human and may not set the machine in its optimum setting.
One difficulty the operator faces is knowing if his/her setting is based on the Perfect Bottle and Label. Ideally the perfect bottle and perfect label lie at the center of a Bell Curve of variation/tolerance. If the operator set the machine based on samples that are not at the center of their bell curve of variation, then the labeling results will offset slightly and the maximum label shift will be more than the theoretical addition of just the product and label tolerances.
It’s a good idea to allow between +/-0.5mm and 1.0mm variation for the Operator set up.
2.4 Machine Variation
The Labeling machine variations come from a few different sources. While many variation in machine label placement can be attributed to the set-up, the following discussion covers the case where the set-up has been completed to optimal settings.
- Label Tracking
- Product Sensing
- Label Gap Sensing
- Label speed and product label surface speed mismatch
With Round and Flat Bottles, the LabelOn™ variation in label placement will be within +/- 1.0mm usually much better.
With Oval Bottles, the LabelOn™ variation in label placement width wise will be within +/- 1.5mm usually much better , height variation remains within +/- 1.0mm usually much better.
3.0 Assessing Samples
Visually looking at samples can give us an accurate confidence level. To do it properly, we need to know the tolerances we are likely to encounter.
In the cases of Labels and Packaging, these tolerances are usually available from the respective manufacturers. Often people cut costs and go to cheap packaging suppliers where these tolerances are not available.
The machinery we supply is based on the products being labeled remaining within tolerance and NOT presenting ANY complex contours.
The size of the label needs to allow for the above listed ADD up of tolerances.
Our label partners need to thoroughly understand the source of the tolerances and insure
THE SIZE OF THE LABEL DOES NOT EXCEED THE DEFINED LABEL PANEL LESS THE SUM OF ALL TOLERANCES; see examples below:
3.1 Example Round Bottle Label Height:
- A round bottle with total height 100mm diameter 25mm and label panel height 75mm needs labeling
- The manufacturer of the bottles states a height variation +/- 1% = +/- 1mm
- The label Manufacturer states a slitting tolerance +/- 1mm
- Operator skill allowance of +/- 0.5mm
- Labeling Machine tolerance is +/- 1mm
- Total tolerance is +/- 3.5mm
- Therefore maximum label height should be 75mm less 7mm = 68mm
3.2 Example Flat Bottle
- A flat Bottle with total height 150mm, Width 80mm, Depth 40mm has a label panel height 80mm and width 75mm needs labeling.
- The manufacturer of the bottles states a height and width variation +/- 1% = +/- 1.5 mm height and +/- 0.8mm width.
- The label Manufacturer states a slitting tolerance +/- 1mm (this affects height placement only)
- Operator skill allowance of +/- 0.5mm (this affects both height and width placement)
- Labeling Machine tolerance is +/- 1mm(this affects both height and width placement)
- Total tolerance is Height +/- 4.0mm , Width +/- 2.3mm
- Therefore maximum label size should be Height 80mm less 8.0mm = 72mm, Width 75mm less 4.6mm = 70.4 mm
Exaggerated Diagram to quickly conceptualize:
3.3 Example Oval Bottle
- An Oval Bottle with total height 150mm, Width 80mm, Depth 40mm has a label panel height 80mm and width 75mm needs labeling
- The manufacturer of the bottles states a height and width variation +/- 1% = +/- 1.5 mm height and +/- 0.8mm width
- The label Manufacturer states a slitting tolerance +/- 1mm (this affects height placement only)
- Operator skill allowance of +/- 0.5mm (this affects both height and width placement)
- Labeling Machine tolerance is +/- 1.5mm in the width direction and +/- 1.0mm in the height direction
Total tolerance is Height +/- 4.0mm , Width +/- 2.8mm - Therefore maximum label size should be Height 80mm less 8.0mm = 72mm, Width 75mm less 5.6mm = 69.4 mm
4.0 Samples Stages
We need sample labeled bottles or pictures at the assessment phase. Other reasons we look at samples, to those covered above, is to identify things like:
- Recessed label panels
- Round bottles where the label panel has a smaller diameter than other areas of the round bottle or its cap
- Round bottles that may have a taper
We later need larger quantities of samples and Labels for testing the machinery so the client knows what to expect prior to shipment and so the client can approve a machine prior to is shipment.
The cost of getting these samples to our manufacturing in the US or abroad is for the account of the client.
The cost of us running the samples is for the account of LabelOn™.
The cost of returning samples separately to a purchased machine is for the account of the client.
