Semi-Automatic vs. Automatic Label Applicator: Which Labeling Solution Do You Need?
While the names imply that an automatic label applicator is faster than a semi-automatic label applicator, the differences go far beyond speed. Choosing the right labeling solution is a matter of matching up the machine design to the types of labels you use, the types of packages you want to label, and the speed of your production line.
What’s the Difference Between Semi-Automatic and Automatic Labeling Machines?
Both types of machines automate the labeling process, but they differ in how they are loaded and activated.
Semi-automatic applicators apply labels on containers that are already lined up. The machine can be hand-loaded for small product batches or integrated into your existing production line for fast labeling. The label is applied when triggered by a switch operated by a worker or a connected machine.
Automatic applicators have a system to position the container before label placement. Once in the correct position, the label roll dispenser applies the label. Some automatic label applicators can also reposition the container multiple times to apply several labels, ensuring efficiency and high-quality label placement.
Operating Costs
With semi-automatic labelers, a worker needs to be on hand to operate the machine. However, added labor costs may be minimal if you already have someone doing a final inspection before product labeling.
Fully automated machines can cost tens of thousands of dollars. However, they fit in line with production and need little human intervention aside from calibration and spool changes. Other considerations aside, the added up-front cost can lead to savings over time from reduced labor costs.
Package Flexibility
Semi-automatic label applicators are almost always constrained to one type of container, whether it’s round, oval, or rectangular. There are even models available for specific containers, like wine bottles, e-liquid bottles, cosmetic containers, and standard shipping boxes.
The more specialized the machine is, the less time it will take to set up. However, this can limit the flexibility of your production line.
Automatic labeling systems are available to accommodate a range of products, letting you change container sizes (and even shapes) on the production line. However, it will take some time to configure the machine for each type of container and label. But once the initial setup is complete, you have the versatility to go back and forth between label placements and sizes.
Speed Comparison
Speed is less important than you would expect when choosing between these two designs. Semi-automatic labeling machines are available that can work at speeds as little as 15 containers per minute, as are automatic labeling applicators (though automatic systems are typically used for high-speed production needs).
Some semi-automatic labelers can reach speeds of 1800 labels per hour. However, actual application rates will vary depending on container and label sizes. Instead, speeds are quoted based on the length of labels that can be spooled out each minute. All things being equal, a machine placing small labels has a higher output than one placing large labels.
A high-performance, durable, industrial automatic labeler, like the 360a Series Form, Fill, and Seal Labeler, can reach speeds of over 6000 labels per hour, depending upon size.
Space and Power Requirements
Tabletop models sit on top of a table that either needs to be in a comfortable position for the operator or in the path of the production line. Other models are stand-alone and have to be lined up with the production line. (At CTM, we use mounting stands for our equipment that can roll into place and raise or lower the entire machine, making it easy to position.)
Even large machines can run on 120-volt electricity. While 15 amps can be supplied by almost any standard outlet, you may need an upgraded outlet and circuit for 20 amp machines. Machines with air-blow applicators and pneumatic functions also need a source of compressed air.
Print and Apply Systems
Another factor to consider is whether your operation requires and print-and-apply label applicator or a system that applies pre-printed labels. If your labels include variable data like barcodes, expiration dates, or batch numbers, label printers can connect to your application system to ensure each product is labeled with real-time, accurate information.
Types of Label Application Methods
Choosing between a semi-automatic or fully automatic label applicator isn’t just about production speed and labor costs — it also depends on the method of label application. Different labeling techniques, such as merge, air-blow, and tamp application, require varying levels of precision, speed, and contact with the product. Some methods, like merge application, work seamlessly with both semi-automatic and automatic systems. Others, like air-blow and tamp, are typically used in fully automated setups to ensure accuracy and efficiency. Understanding these application methods can help you determine the right labeling solution for your production needs.
Merge (Wipe-On) Application
Also known as wipe-on application, merge labeling applies labels by matching the speed of the conveyor, ensuring a seamless adhesion as products move past the applicator. This method is highly adaptable, allowing for left- or right-hand operation with a simple conversion. Merge applicators can apply labels to the top, bottom, or sides of a product.
Air-Blow Application
Air-blow applicators use a burst of compressed air to apply labels without direct contact, providing greater flexibility in label positioning and orientation. Unlike merge applicators, air-blow labeling does not require conveyor speed matching, allowing for faster application rates and more precise label placement. Labels can be applied in the opposite feed direction, parallel, perpendicular, or even at a 45-degree angle.
Tamp Application
Tamp labeling combines precision with the ability to apply labels at a greater distance from the applicator using an air cylinder. This makes it an excellent choice for hard-to-reach areas, such as between guide rails or on the side of a pallet. Each label size requires a matching vacuum pad, ensuring secure application. Tamp applicators can label from multiple angles and specialized configurations, like swing-arm tamp (applicator that can swing out to label the leading side of a product), dual-action tamp (label two different sides of a product), or corner-wrap tamp (wrap around labeler).
Hidden Taper: The Most Common Issue with Labeling
“Drafting” makes the container easier to release from the mold and helps get the desired surface finish. As a result, even apparently flat-sided round and oval containers have slightly angled surfaces, requiring taper adjustment. Without this adjustment, the label will start to go on straight, but by the time it wraps around the bottle, the end can curve over the lid. When choosing your next machine, make sure it can handle the containers you use, no matter how straight they appear.
Use Cases for Labeling Machines
Labeling for a Range of Container Sizes
Containers are loaded into our Tabletop Vial Wrap System’s magazine by hand or by lining it up with a conveyor belt. From there, a star wheel picks up vials and carries them to the labeler. Each bottle spins in place as the label is applied. Different bottle sizes can be used by switching out the star wheel. This makes it ideal for packaging a range of pharmaceuticals and cosmetics.
Easy Product Switching
The 360a Series Wrap System is a basic, low-cost machine designed for wrap labeling round containers. After the initial label calibration, the onboard computer can recall the settings. This eliminates the need to recalibrate when switching products.
Flexible Bottle Labeling
Even if you only make one product, you may need to handle several container variations. For example, wine bottle shapes vary depending on their contents, so bottle labelers need to be able to work with a range of shapes and diameters. These machines can be used in several configurations, applying a single wrap label, front and back labels, and cover labels.
Applying Multiple Labels on Food Products
Our 360a Series Top Bottom Split Conveyor loads containers horizontally and can apply labels to both the top and bottom of a product. Stainless steel construction, paint-free surfaces, and a gap-free conveyor belt prevent rust, paint, and food debris from contaminating food products.
Labeling Cylindrical Containers
If your product comes in a cylindrical container like bottles or jars, choosing the right round bottle label applicator can significantly impact production speed and accuracy. For businesses needing flexibility with different container sizes, semi-automatic bottle label applicators provide control, while automatic labelers ensure speed and consistency.
Our Bottle Labeling Machine — Vertical Trunnion Roller ensures consistent application at high speeds while being able to completely wrap five different labels up to 45 PPM. No matter your production needs, the right labeling solution can help you scale without sacrificing quality.
Get a Consultation to Find a Labeler that Fits Your Needs
If you need a semi-automatic label applicator or a fully automatic label applicator for your business, CTM Labeling Systems is here for you! We can direct you to a local distributor who will set you up with a machine that will fit your custom needs.
