What You Need to Know Before Investing in An Automatic Label Applicator
The pressure sensitive label market continues to grow, with an estimated value of $93 billion worldwide. Why are they so popular? These labels are available in a wide range of materials to fit almost any need. They’re also easier to apply than competing technologies, including wet gluing and shrink labeling. Even with these advantages, an automatic label applicator is still a big investment. How do you know it will be a good fit for your production system, both now and in the future? Asking these questions will help you find a labeling system that will increase your production speed and reduce packaging errors, while being able to grow with your business.
Is it Time to Upgrade Your Labeling System?
In the past, the standard advice was to upgrade once the machine can replace one worker. As labor shortages increase, anything you can do to reduce the workload on your staff can pay huge dividends. Automating your labeling system also decreases labeling issues and product damage, reducing your overall bottom line. If you’re switching from a manual or semi-automatic system, or you’re adding a new production line, the return on investment may be faster than you think.
Automatic labeling machines come with state-of-the-art technology that makes product labeling a breeze, such as touch screen operators that streamline machine diagnostics and printing set-up.
Which Label Applicator Machine Best Fits My Packaging?
There are several ways a pressure sensitive label can be applied to containers. Each method works best for a specific application.
Merge: A wiper or brush pushes the label onto the side of the container. This type of labeler is great for high speed application, but the product loading speed must match the labeling speed.
Air-blow: This applicator uses a burst of air to push the label onto the container. This works well for uneven surfaces, and it allows the label to be applied at any angle. It’s also great at handling variations in product loading speed.
Tamp blow: The tamp uses muffin fans to keep the label in place. After the tamp moves over the container, a burst of air pushes the label onto the container. This is the best choice for hard-to-reach areas or if you need to allow for greater distances between the machine and the product you’re labeling.
How Fast Can It Label My Containers?
If you’re upgrading from a semi-automatic label applicator, you could see labeling speeds triple. Making the jump from hand-applied adhesive labels? A high-performance, fully automatic machine can label products up to 10 times as fast.
Application speed is measured in inches per second. However, this is just one factor of many that determines the maximum output of a labeling system.
Splitting up labeling tasks increases speed. For example, if you run a single web with alternating front and rear labels, the container has to stay at the labeler until both labels are applied. Split these labels across two webs and applicators, and one container can get a front label, while a second gets its back label. This nearly doubles labeling speed. Alternatively, our 360a Top Bottom Split Conveyor applies both labels at the same time using two webs. The container doesn’t need to be reoriented for the second label, maximizing application speed.
The package must be steady for accurate label application. Adding conveyor belts, rails and rollers keeps containers from wobbling or veering away from the applicator. These steps increase labeling time, but they’re necessary for accuracy.
Downtime also needs to be considered. Switching to larger reels lets the machine run longer between reel changes. If you’re considering a print-and-apply system, you also need to manage print engine supplies. Thermal transfer printers have ink tapes that need to be replaced, while direct thermal printers only need the occasional print head replacement.
Does it Work With My Current and Future Containers?
Even for products with standard sizes, there are several packaging variations. For example, while a standard wine bottle holds 750 mL, there are several bottle shapes in use for specific types of wine. Choosing a bottle label applicator with some adjustability lets you cover more of your products, and gives you the option of changing containers in the future. For example, our wine bottle labeling machine is designed to cover all common sizes, including standard and magnum bottles.
Want to use one machine to cover several product lines? Our automatic label applicators store calibration settings, making it easy to switch between container sizes.
How Can I Upgrade this Automatic Label Applicator?
Choosing a system that can grow with your needs can save you a substantial amount of money down the line. It also reduces downtime, since upgrading doesn’t require changes to floor space, interface, or power requirements. There are three key factors to consider: applicators, label compatibility, and printing technology.
Number of applicators: How many labels do you need on your products? Do you want to use just one wrap-around label? What about front, back, and side labels? Does it make sense to run a single label web now, then switch to multiple webs as production increases?
For example, our custom glass bottle labeler is set up to support several common labels, including wrap, neck, tamper-evident and front and back labels. You can start with a simple configuration, then add more applicators to your labeling system as you need them.
Clear labels: Since most labels are opaque, automatic label applicators come with label sensors that detect the beginning and end of the label based on light. To use clear labels, this sensor is replaced by one that measures resistance. Resistance goes up when it has to pass through both the label and backing, then down when it only passes through the backing. This lets the machine know the exact position of the label, whether it’s clear or opaque.
Printing technology: Print engines can print by heating thermal paper, or by melting ink onto the label. Fortunately, most print engines support both types of printing. Each print engine model has different limits for minimum and maximum label sizes. We offer engines from Zebra and Sato, some of the largest manufacturers of industrial printers. This lets you choose an engine that supports the label sizes you need for your products.
How Can I Integrate an Automatic Label Applicator into my Operating Technology System?
By connecting your labeling machine to the rest of your OT system, you can monitor your labeling equipment. It also lets you send information needed for label printing, including serial numbers and best by dates. We offer our machines with a variety of common interfaces, including RS-232, Ethernet and Wi-Fi, making it easy to connect to the rest of your system.
Can a New Labeling System Give You New Packaging Options?
Automation doesn’t just speed up labeling. It also gives you more label options. For example, thanks to adhesive improvements over the past few years, it’s possible to add pressure sensitive labels to aluminum cylindrical containers. This lets small manufacturers buy small lots of blank cans instead of buying pre-printed cans by the truckload. Craft brewers use this to switch from glass to aluminum, because cans are less prone to breakage and are cheaper to ship.
Start Your Labeling Solution Search with Us
Does finding the right automatic label applicator seem overwhelming? When you contact CTM Labeling Systems, we’ll get you in touch with your local distributor. They will work with you to find a labeling solution that fits your current production needs and can grow with your business.
