Diagraph's Blog

Avoid Labeling Mistakes by Removing Plant Air

Mon, 31 Jul 2023 14:00:00 GMT

The process of applying labels in the packaging industry is a critical aspect of production that demands precision and speed. Transitioning to all-electric label applicators can significantly enhance this process by eliminating the reliance on plant air, resulting in cost reductions and fewer instances of misapplied or missing labels. Advantages associated with implementing all-electric label applicators in manufacturing operations are listed below.

Gain precision and accuracy through applicator control

The closed-loop speed control and setting capabilities of servo motors in all-electric labelers ensure consistent and repeatable label placement. Achieving this level of consistency is considerably more challenging for pneumatic labelers that rely on plant air. When a pneumatic labeler connects to the plant’s main air line, air pressure availability for optimal tamp movement cannot always be guaranteed. This is because air pressure availability depends on how many other pieces of equipment are connected to or using the main air line in that moment. If the air pressure is insufficiently distributed and falls below the required level, the actuator may not fully engage or may take longer to engage leading to inaccurate label placement on the moving target. In some instances, the label may not adhere to the product at all.

Compared to pneumatic systems, all-electric motors remain unaffected by other equipment in the facility and need only a standard 110v plug, providing flexibility in positioning, redundancy and backup equipment. Moreover, the electric motor can regulate the tamp’s application force, as it operates with a sensor on the tamp pad that detects the product and communicates its location to the tamp. If the product is not in the expected position, the tamp adjusts accordingly to apply the label.

In a pneumatic system, the tamp is fully discharged with a burst of air. If the product is positioned too far away, the tamp will miss it. Conversely, if the product is too close, the tamp will hit it with excessive force, leading to label misplacement or possible damage to the product or the tamp arm.

Maintain precision and accuracy through label control

Controlling the label on the tamp pad is a significant challenge with print and apply label applications. In applications that utilize pneumatic air, a vacuum is required to secure the label on the tamp pad. This vacuum is created by consistently directing air across small holes in the tamp pad, holding the label in place. However, inconsistent plant air pressure may hinder the formation of the vacuum across these holes, resulting in the label falling off before it reaches the product. Furthermore, dirty plant air containing oil, water, dust or other contaminants can lead to clogged holes, diminishing vacuum efficiency and causing the label to detach prematurely. For the vacuum to be effective, all holes on the tamp pad must be covered by the label.

In contrast, an all-electric system circumvents the need for plant air by employing an independent vacuum fan, located on the back of the tamp pad, to control suction. This approach eliminates potential interference from other equipment, reduces contamination risks and removes the requirement to cover all the holes. This system utilizes a single focus vacuum fan to draw air through each hole individually, ensuring the label is securely held in place during transit. Because the fan pulls air through each hole, only half the holes need to be covered by the label, offering users the flexibility to run various label sizes on the same applicator. Even when a smaller label size is used, the label will maintain its vacuum and not detach before reaching the product.Top of Form

Protect your liner and protect your uptime

After the label is removed from its liner, the liner needs to be wound back onto a roll. The rewind is important to provide tension on the backing so that as it pulls across the peel blade, there is enough pull to peel the label off so that it can be applied onto the product. All-electric labelers control the re-wind of the label rolls more carefully, using brushless DC motors that are automatically tensioned with a Kevlar belt and no clutch. This solves the customer problems of needing a consistent label feed and being able to handle a long label take up without run on. These things add up to increased lead time. Pneumatic systems employ a clutch that requires adjustments as well as replacement for the brush motors that wear out. The gear boxes can also require replacement. If these wear parts are not maintained, they can result in label jams and liner breaks (from over tensioning) causing downtime. Additionally, the liner can drift, causing the print to drift on the label and poor or no scanning/ readability on the barcode or label.

Conclusion

All-electric label applicators revolutionize the packaging industry by eliminating the reliance on plant air, providing precise applicator control for consistent and accurate label placement and ensuring secure label control for various label sizes. These advanced systems protect the liner, enhance uptime and reduce maintenance costs, resulting in increased productivity and efficiency. Embracing the power of all-electric label applicators empowers manufacturers to streamline operations, reduce errors and deliver products with consistent and reliable product identification. Contact us today to learn more.

Smart Sensors Gives Automated Print‐And‐Apply Systems a Big Advantage

Wed, 17 May 2023 05:01:00 GMT

Effectively moving products through manufacturing and into the retail supply chain requires a robust track‐and‐trace capability. You need to know when products came off the line, where they’re located and where they’re headed. In production environments that integrate manufacturing, packaging and shipping operations, the final step in this process is pallet labeling.

Manufacturers that operate on a relatively small scale with a limited number of SKUs and shipments to only a few distributors or customers may be able to keep pace with manual pallet labeling processes. But high‐volume manufacturers that produce a variety of SKUs and prepare shipments to many destinations should consider an automated print‐and‐apply labeling system that supports higher throughput with lower unit costs.

Diagraph offers an all‐electric print & apply pallet labeling system, freeing manufacturers from the potential inconsistencies often associated with conventional pneumatic labelers. And, since inconsistencies in pallet labeling have the potential to disrupt production and delay outgoing shipments, it’s critical to ensure your labeling solution delivers reliable results, shift after shift.

To ensure uptime and maximize labeling consistency, Diagraph’s latest all‐electric print‐and‐apply labeling machine incorporates a variety of smart sensors that are engineered to detect potential problems and make automated adjustments on the fly. By incorporating smart sensors into our labeling solutions, we can help manufacturers maximize uptime, minimize or eliminate errors, and make it easier than ever to ensure compliance with customer labeling requirements.

With smart sensor technology, a Diagraph print‐and‐apply labeling system can do things such as:

Detect a missing label at the peel point and automatically advance the web past the missing label area to prevent double feeds and missed products
Automatically monitor and adjust the application speed and pressure for every label to keep the system in sync with the production line even as the system ages
Use sophisticated tamp sensors to ensure proper label application and placement across a wide variety of applications, including multi‐label applications and complex corner‐wrap label applications
Automate adjustments needed to accommodate a wide range of label sizes for your product lines while minimizing or eliminating unproductive downtime

In addition to smart sensing technology, Diagraph’s automated all‐electric PA7100 print‐and‐apply labeling machines employ Zebra ZE500 Series OEM thermal printer engine. This thermal printing technology delivers industry‐leading durability and performance anywhere 4‐ or 6‐inch labels are needed. One of the key advantages of Zebra’s print engine is all‐metal construction, which ensures long‐lasting durability. They also employ printer management tools that help detect problems before they impact productivity, making them the perfect companion to our smart sensor technology.

If you would like to learn more about the innovative technology that Diagraph builds into automated print‐and‐apply labeling systems, contact your Diagraph representative. We’ll be glad to show you how our industry‐leading approach can help you prepare shipments for the retail supply chain more efficiently.

Focus on Pallet Labeling Workflows to Maximize Efficiency

Wed, 15 Mar 2023 05:01:00 GMT

Many factors determine the profitability and performance of a manufacturing operation. For example, every experienced manager knows the importance of understanding and controlling the cost of raw materials, labor costs, capacity utilization and quality assurance to maximize bottom line results.

As manufacturers hone the efficiency of their operations, however, they also know the importance of looking beyond the obvious variables to evaluate and improve the performance of less apparent workflows. These processes may seem secondary to core production activities on the surface but they will have an outsized impact on results if they can’t keep pace with operations. One of the less apparent workflows that efficiency‐minded managers should focus on occurs right at the end of operations: pallet labeling.

High‐volume manufacturing operations that ship products to a variety of distribution channels simply can’t afford a slowdown in production caused by breakdowns, errors or low capacity in labeling systems as pallets are prepared for distribution.

The answer for most manufacturers to supporting increased productivity is an automated print‐and‐apply labeling machine that eliminates the productivity limitations of manual processes and streamlines labeling workflows. The production rates of automated print‐and‐apply labeling machines vary depending on the labeling method used and the number of application points, but a standard tamp system should be able to label 120 products per minute.

Automated print‐and‐apply labeling machines also deliver quality control benefits because human error is largely eliminated from the equation. Instead of inconsistent label placement that can slow shipments or even result in a customer rejecting a pallet, an automated labeling system helps ensure every pallet is labeled in compliance with customer requirements and expectations.

WHAT IS THE BEST WAY TO AUTOMATE PALLET LABELING?

While some labeling machines rely on pneumatic systems to apply labels, maintaining highly consistent PSI in compressed air systems is challenging for manufacturing plants. These challenges can lead to inconsistent performance and difficulty troubleshooting problems.

The better alternative is the Diagraph PA7100 all‐electric print‐and‐apply machine which offers reliability and performance that can’t be matched by traditional pneumatic‐based labelers.

The Diagraph PA7100 all‐electric labeling machine relies on industry‐leading technology to reliably print and apply labels in a variety of applications including the top, sides, bottom or corners of pallets. These solutions are fully customizable to apply self‐adhesive labels at varying heights, distances and speeds. The all‐electric design eliminates the potential inconsistencies of pneumatic alternatives—producing consistent results no matter how many units move through production.

A key to the performance of Diagraph’s all‐electric print‐and‐apply labeling machines is the usage of industry‐leading Zebra OEM thermal print engines. Zebra is a leader when it comes to 4‐ and 6‐inch thermal labels, using all‐metal construction for long‐lasting durability and delivering print speeds that allow our print‐and‐apply labeling machines to keep pace with high‐volume production lines.

For 130 years, Diagraph has been helping manufacturers make the perfect mark, pairing technology and service to deliver complete solutions. To learn more about our automated all‐electric print‐and‐apply labeling machines for pallet labeling, contact your Diagraph representative.

How do I get labels to stick in hot and humid environments?

Mon, 16 May 2022 16:11:00 GMT

When it comes to labels used in packaging, not all are made the same way. Specific environments, like hot and humid, wet or frozen, will require a compatible label material to stay adhered properly to packaging. It is crucial that labels are readable, scannable, and safe to use and dispose of. To meet compliance, labels must remain adhered for consumer and retail-use despite the environmental factors the labeled package has to endure.

Common Issues with Labels in High Temperature Environments

Something to be aware of when considering using labeling for product identification in a hot or humid environment is that labels are sensitive to temperature, making facility environment temperature a determining factor in choosing what label material to use on a product.

Some common issues with labels as environmental temperatures rise:

Labels not dispensing properly and causing applicator jams
Labels adhering to the roll instead of onto the product
Label liner peeling or curling
Labels falling off

As summer kicks in, and temperatures rise, adhesive related problems will affect the quality of a label -- making it difficult to peel from the labeling machine and to stick to the product. Adhesives, the pre-applied glue specially engineered to perform on pressure sensitive applications, get softer and edges get tackier resulting in labels that are difficult to remove off the original roll. Strong adhesive can make release of these labels from the roll a struggle. Dispensing issues caused by adhesive can disrupt product labeling and lead to damaged labels and jammed applicators.

A label liner is likely to expand or curl with high humidity, causing the adhesive to ooze. This curling liner makes label processing challenging in a printer or label applicator. Also, the ooze from the adhesive can cause printer jams and damage to the printheads.

Best Practices for Label Storage in Extreme Temperatures

Even the most pressure-sensitive label adhesives soften as temperatures rise. Hence, storing labels properly can make the difference between a label that survives these changes in weather versus the one that will peel or deteriorate.

Some ideas for storing label rolls properly and protecting them from the heat include:

Have label rolls sit upright. Do not lay them flat if possible, to prevent sliding on the liner.
Store your label rolls in plastic bags to decrease humidity exposure.
Store label rolls lower to the ground to reduce their exposure to top-shelf temperatures that can be 20° to 30° hotter.
Fan the label stack helping to improve label processing.
Use a utility rack with hanging dowels to store label rolls.
Store label rolls by stacking them end-to-end.

Understand Labeling from the System to the Consumables

Many environmental factors must be called into question when assessing the labeling process. Temperature is only one of many considerations to determine how to effectively apply labels to product. Our Diagraph specialists are well-versed in providing site evaluations aimed at determining the best fit application for your labeling operation. Whether the survey is conducted on-site or virtually by answering a series of determining questions, we are here to help you understand your labeling solution options and what it looks like in even the most extreme industrial environments. Reach out to us today to start your evaluation.

Superior labeling power source — pneumatic air/electric labeling

Sun, 15 May 2022 16:13:00 GMT

There is a debate in the packaging technology industry on which is a superior labeling power source for automated labeling equipment — pneumatic air or electric? Pneumatic labeling systems are built around timing-based commands that drive label movements depending on the reliability of the pneumatic air supply, while all-electric labeling systems are built around real time data-based commands that allow for total control of the labeling process.

The difference between the two approaches is night and day — like the difference between VHS and high-resolution digital streaming technology. The more manufacturers understand the advantages of all-electric labeling, the more pneumatic systems will go the way of VHS tapes and rotary phones.

Every labeling system, regardless of core technology, can incorporate sensors for feedback. Recall the times you have seen a product strike a pneumatic labeler’s actuator arm while moving down the packaging line. This happens all too often with pneumatic labelers because the control of the label feed and actuator arm is not reacting to real-time feedback from sensors. Instead it is following pre-programmed timing commands and relying on the programmed settings for the pneumatic air supply (regardless of the actual pressure in real-time).

Free from the timing control constraints found in pneumatic air powered machines, Diagraph’s all-electric labeling systems can interpret feedback from smart sensors in real-time to allow for total control of the label throughout transit. Combining strategically placed sensors with brushless DC servo motors allows Diagraph’s labeling systems to operate with extreme precision, guaranteeing one-to-one label-to-product matching time after time. The all-electric, servo-driven actuator maintains speed consistency, while “smart” sensors confirm that a label is present for application, and even provide the ability to control impact on the product being labeled. The system doesn’t have to rely on inconsistent air pressure to manage this process.

Another advantage of the all-electric method over the pneumatic air method centers around the tamp pad. Pneumatic driven label applicators utilize venturi vacuum technology to control the transit of the label from the tamp pad to the product. Nearly the entire surface of a pneumatic machine’s tamp pad needs to be covered by the label to maintain proper suction. Unlike pneumatic machines, Diagraph’s all-electric label applicators utilize an electric fan to create vacuum, allowing Diagraph labelers to accommodate multiple label sizes utilizing a single tamp pad. This saves time during label size changeovers as well as money.

With 130 years in the marking and coding industry, Diagraph has a rich history of providing highly durable and reliable labeling and inkjet solutions. Diagraph was the first to offer all-electric labeling solutions to handle all modes of label application including tamp, swing and tamp-blow. The result is a robust lineup of automated labeling solutions that offer benefits only found in all-electric systems that don’t compromise on labels sizes or performance.

Click here for a comparison of all-electric and pneumatic labeling systems.

Increase contract packaging productivity by minimizing equipment interventions

Tue, 02 Mar 2021 21:49:14 GMT

Marking and coding equipment should help contract packagers improve productivity. Diagraph accomplishes this by keeping equipment intervention requirements for our product identification equipment to a minimum.

We design and manufacture coding and labeling equipment to last longer
We are focused on operator and maintenance team product training
We partner with customers to develop a proactive game plan that keeps their coding and labeling equipment well utilized and appropriately upgrade

Designing Coding and Labeling Equipment to Last

Diagraph’s coding and labeling equipment runs cleaner for longer between required interventions and withstands wear and tear, increasing its useful life. This leads to greater equipment uptime and a stronger return on investment over the life of Diagraph equipment.

The number of steps required for routine interventions as well as the length of time between those interventions is minimized. Product capabilities like automatic printhead cleanings help keep inkjet coders operating with optimal print quality for longer. Examining consumable replenishment practices and centralizing ink refills or providing a quick turn label stock webbing approach makes required interventions quicker and hassle-free.

Finally, quality materials and thoughtful engineering matter when it comes to the longevity of your equipment. Diagraph’s focus on impact resistant designs – whether it be an inkjet coder or a labeler – ensures long-term product reliability.

Setting People Up for Success

After making sure your product coding equipment is properly matched to your application and contract packaging environment, it is essential to make sure your line operators and maintenance staff know how to properly handle and maintain your equipment.

Diagraph’s equipment is designed to have fewer touchpoints to enable hassle-free installation, training and maintenance. These easy access touchpoints minimize the amount of time required and eliminate the need to access the entire system to perform maintenance or changeovers.

Because contract packagers regularly deal with worker turnover challenges, routine training to keep workers knowledgeable and able to be good stewards of your equipment is critical. We offer refresher-level training opportunities with each scheduled service visit from a Diagraph field service engineer. In addition, in-depth training is offered on location or at the Diagraph training facility in St. Charles, Missouri.

Partnering to Develop a Game Plan

Our most successful customers partner with us to regularly evaluate and maintain their coding and labeling equipment. We perform routine equipment assessments, provide regularly scheduled service and develop long-term equipment upgrade plans.

Equipment is kept running longer and the need for unplanned interventions is reduced by staying ahead of wear-caused failures and by properly maintaining equipment. As with all things electro-mechanical, equipment performance will eventually impact production throughputs. We help you navigate the useful life of your equipment to determine when to repair and maintain a system and when to upgrade and benefit from performance and feature enhancements.

By working closely together, our account teams can help you develop a multi-year plan that provides measurable cost savings opportunities due to system efficiency gains and consumable usage optimization. These strategic audits also help customers strategically sequence system upgrades of their older technologies to avoid the sticker shock created if your product identification equipment fails at the same time.

Our goal is to always to make it easy for our customers to make the perfect mark. Find the right product for your application by completing this short assessment.

Call us today at 800.722.1125 to learn more about how Diagraph partners with manufacturers to achieve product identification and packaging compliance success.

How to Pick the Best Product Identification Solution

Tue, 17 Mar 2020 16:31:12 GMT

Step one of a manufacturer’s game plan for packaging compliance is to understand your manufacturing code and print application requirements, in order to pick the product identification solution that is best for your needs.

Print Message Requirements

What kind of information needs to be included in your print message? In many cases, especially in food and beverage, consumer-readable information must be included for buyers to determine freshness. In other instances, government and global regulatory agencies have set the requirements for manufacturers to adhere to. In order to meet packaging compliance, manufacturers may need specific product information, manufacturing codes, and barcode information, including:

Product Information
- Product Name
- Product Description
- Quantity/Counts
- Ingredients
- Nutrition Facts Panel
Manufacturing codes
- Batch Code
- Lot Code
- Line Code
- Operator Code
- Date Code – Manufactured On or Expiration Date
Barcode requirements
- EAN/UPC
- 1D
- 2D
- GS1-128
- GTIN-14
- ITF-14
- Other available barcode formats

Once specific print requirements and message placement are determined, manufacturers should also consider their application specifications. What type of packaging substrate does a manufacturer’s product or products use? What other processes in your material handling are occurring to take into consideration? And what kind of line speeds are they trying to achieve?

Application Requirements

It will be important to understand which criteria your application falls under for a marking and coding partner to best match you with a solution that will deliver your desired results.

Packaging Level
- Primary Packaging
- Secondary Retail Ready Packaging
- Case Level Packaging
- Pallet Level Labeling
Product Packaging Substrate
- Glass
- Metal
- Plastic
- Paperboard
- Cardboard
- Shrink wrap
- Other
Integration
- Form fill and seal machines
- Traversing equipment
- Case sealing
- Case gluing
Line Speed and Product Throughput
- How many feet per minute or products per minute do you hope to achieve?
- Under 500 fpm or over 1,000 fpm?
Environment
- Cold or refrigerated facilities
- Hot, humid processing plant
- Dusty environment with debris and other small particles around the conveyor line

After determining the print requirements and application specifications, manufacturers can look at the available product identification solutions and select a technology that is right-sized for their material handling set-up.

Available Product Identification Solutions

A full portfolio range of product identification solutions are available to manufacturers including:

The tables below show how each type of product coding technology is suited to fill specific manufacturer print and application requirements.

In order to achieve packaging compliance, it’s necessary to pick the best marking and coding technology for the product in question. By taking the time to understand print message and application requirements, manufacturers can begin to compare compatible product identification methods and equipment.

Picking the best product identification solution is one step in a multi-step process to achieve packaging compliance. After the information has been applied to your product, message validation is the next step.

Message Validation

Ensuring manufacturing codes are printed on products is not enough by itself to achieve packaging compliance. The codes need to be validated to make sure they are present, accurate, and scannable.

There have been many advancements in product identification and machine visioning technology that have enabled manufacturers to automate the monitoring of real-time print quality. Scanners and vision systems are common components added to the production line postprint to inspect and report any illegible codes or incorrect stock.

Levels of Message Validation

Level 1: Present - Confirm a print occurred on the product without any indication of accuracy
Level 2: Accurate - Confirm a print occurred and it correctly matches the data requested by the printer
Level 3: Scannable - Confirmation that a print occurred, it correctly matches the data requested by the printer and is a scannable, readable mark

Manufacturers know their requirements best, and working with a partner that offers a portfolio of all types of product coding technology will give you a fair assessment of the best solution for your needs. It’s also wise to choose someone who can provide support beyond installation for maintenance and servicing as age and wear and tear occur on your equipment. A reliable partner will also provide training for your maintenance staff should you choose to be as self-sufficient as possible.

However, there are still more steps to ensure manufacturers achieve packaging compliance.

Learn more about the other key considerations Diagraph recommends for guaranteeing packaging compliance:

Discover which Diagraph solution is right for your application by completing our short technology assessment. Click here to complete the assessment.

Your Guide To Automating Your Pallet Labeling Process

Fri, 14 Jun 2019 21:36:00 GMT

Download the full whitepaper, “Pallet Labeling: The Final Step In Your Production Tracking Process”

The final step in your production process can often easily be overlooked. After rigorously completing all the upstream processing, packaging and coding processes, the final palletized product seems to be a small step before crossing the finish line. However, labeling at the pallet level is a crucial process for identifying palletized products being shipped to retailers.

Imagine this: You’re completing a custom job for products specific to one regional retail chain. To differentiate the pallets for the custom job from your standard products, you plan on printing the identifying batch information on the license plate label and applying it to the outside of the shrink-wrapped pallet. When the time comes, your shipment is sent to the retailer only to discover that the products sent are not the custom printed containers they ordered. Now not only is your relationship with this retailer tarnished, but you are on the hook for reprinting all of their products at your own cost.

This scenario might sound familiar if you’re still in the business of manually applying labels. Some level of human error is always a risk and it can be a costly one. Ensuring a consistent, accurate label on every pallet that leaves your facility doesn’t have to be a trying task. It is possible to guarantee proper label placement while also avoiding common safety issues often occurring from the entanglement of the labeler in the pallet shrink wrap.

Our pallet labeling experts at Diagraph have complied a helpful guide for assessing automated pallet labelers for your production line. This guide steps through the main questions you should ask when evaluating your pallet labeling automation process and reviews the top areas of consideration you should work through before you make any kind of investment.

Download the full whitepaper, “Pallet Labeling: The Final Step In Your Production Tracking Process”, here to learn more.

Key Considerations for Assessing Coding Equipment Uptime

Mon, 24 Sep 2018 01:46:25 GMT

System uptime is the average length of time a piece of equipment runs between interventions are required to keep it operating smoothly. When comparing system uptime when assessing coding equipment, it is important to look at several factors including:

How long a coder can run between consumable replenishment
How long it takes to refresh or restock the coder’s consumable
How long a coder can run between preventive maintenance service intervals

To understand system uptime better, let’s take a closer look at each of these key areas:

Length of time between consumable replenishment

Consumable replenishment is the most common and necessary interaction with any given piece of coding equipment. The amount of time a system can go between consumable replenishment, like adding more ink to an inkjet coder, replacing ribbon stock in a thermal transfer printer, or replacing labeling stock on a labeler largely depends on the capacity of the individual piece of coding equipment. There are additional factors to consider when assessing consumable replenishment.

For inkjet coders, it is important to understand how long a printer can run after the bottle or cartridge of ink has run out of fluids. Does the system provide an advanced notice warning giving a countdown to when the coder will be truly empty? Does it provide enough of a warning that allows for fluids to be replenished at ideal production times like before and after shift changes? Can the fluids be replaced while the system is actively coding?

For thermal transfer printers, ribbon capacity as well as total ribbon usage are important to maximizing the length of time between replacing ribbon stock. For ribbon capacity, look at the maximum size of the ribbon roll for your chosen ribbon type. To maximize ribbon usage, look for thermal transfer printers that offer ribbon saving features that utilize as much surface area of the ribbon before advancing it for ribbon waste collection.

Streamlining consumable replenishment

Although replenish consumables is unavoidable for the most common types of coding equipment, the very act of replacing or replenishing a bottle of ink or solvent, a roll of ribbon, or a roll of label stock can be made easier and less time consuming for system operators.

Inkjet coders tend to be the easiest type of coding equipment when it comes to consumable replenishment since most inkjet coders can keep running while being refilled. Look for inkjet coders that offer mess free, mistake free refill options like needle and septum systems that prevent leakage and dripping when swapping fluid bottles. This is ideal compared to inkjet coders that require fluid bottles to be manually poured into the system. Another factor to consider is how many touches or actions are required to complete the fluid refill process. Look for systems that provide one-touch fluid refill options as well as variations in shapes and sizes between ink and solvent bottles to simplify the process as much as possible while preventing the wrong fluids from going in the wrong compartments.

Due to the nature of thermal transfer printing, the printer will become temporarily unavailable for coding while ribbon stock needs to be replaced. Look for thermal transfer printers that have an easy-to-web design as well as easy to remove and replace ribbon cassettes. Investing in an additional ribbon cassette that can be loaded and ready to go when ribbon is low minimizes downtime on thermal transfer printers as much as possible.

Like thermal transfer printers, automated labelers also become temporarily available for use when label stock needs to be replaced. Look for an automated labeling system that has an easy label webbing design to make it easy to unload spent stock and load a fresh roll. Manufacturers with high production commands benefit from having alternate labeling machines available. When one machine signals that its label stock is low, the other starts applying labels so that the low system can be replaced. This virtually eliminates downtime with automated labelers.

Preventive Maintenance Service Intervals

Although consumable replenishment is required more frequently than maintenance, preventive maintenance procedures take more time to complete and often require the coding equipment to be completely unavailable for printing while being serviced. Not all coding systems are created equal. Service intervals are usually stated in the amount of system hours that can pass before preventive maintenance is required. Things like ink type, manufacturing environment, and overall wear and tear caused by the application can impact recommended system intervals.

For inkjet coders, look for systems that can run as long as a year or more before maintenance is required. Better yet, look for systems that provide advanced warnings about upcoming maintenance so that you can schedule interventions around your production schedule. Another factor to consider is how easy or complicated it is to perform maintenance. Look for systems that have self-contained service modules that can be easily swapped out without the need for a service engineer. Systems that have screen-guided instructions for service interventions tend to be the easiest to use.

For thermal transfer printers, take a look at preventive maintenance requirements that are recommended by the manufacturer. How many parts require replacement? How long does the manufacturer state it will take to perform maintenance? How easy is it to access parts that need to be replaced? These are all important questions to ask when evaluating thermal transfer printers.

When it comes to automated labeling systems, all-electric systems allow you to replace wear parts while relying on pre-programmed settings to get the labeler operating as quickly as possible. Pneumatically operated labeling systems require extensive adjustments after replacing wear parts, making maintenance interventions anything but fast. Also look for labeling systems that offer screen-guided instructions for quick and simple service interventions. Another advantage of all-electric labeling systems over pneumatic is that electric options allow for a gentler application of the label to the substrate. This cuts down on overall wear and tear, allowing the system to go for longer between maintenance intervals.

If you have any questions about how to calculate the uptime of your current coding equipment compared to new coding equipment technology, we are here to help. Contact a Diagraph product identification expert today by calling 1.800.722.1125 or contacting us through our website.

How to Reduce Marking Mistakes and Ensure Proper Code Adhesion

Tue, 04 Sep 2018 17:09:21 GMT

What does your company do when products are marked with the wrong product identification codes? Scrap? Rework? Mismarked and mislabeled products can create big hits to the bottom line. When encountering marking mistakes with regularity, companies can find it difficult to keep profit margins under control. What’s worse is if mismarked or mislabeled products make it out to market, manufacturers can face penalties from retailers and the risk of product recalls.

There are several factors to consider when trying to reduce marking mistakes:

Coding Technology

The first step to reducing marking mistakes is picking the right coding technology for both your application and your manufacturing environment. When choosing a technology, some factors to consider include:

Packaging design and material
Code contrast requirements
Content of print message or label format
Proficiency of available labor
Production throughput and cost requirements

Available coding technologies include inkjet coders, labelers,thermal transfer printers, and laser coders. Each of these technologies have their merits and should be considered carefully with the help of experts familiar with the advantages and disadvantages. Success will be realized when the best technology is chosen for your unique situation.

Ink, Label, Ribbon Match

Choosing the right technology often comes down to identifying the best possible combination of cost-per-mark and mark adhesion quality. There are numerous inks, label stock types, and ribbon formulations that can help you achieve a durable, lasting code on your product.

If you are marking onto a particularly tricky surface or operating your equipment in a hotter or cooler than average environment, you will want to run code adhesion tests and even demo the full solution for a period of time to ensure that code adhesion is strong once a mark is applied to your product packaging. A quality supplier will be able to run print samples and set you up with trials of their equipment.

Material Handling Before Product Coding

Although choosing the right equipment and matching it with the right ink, label or ribbon is important, an often-overlooked aspect of achieving code compliance is material handling. Heavy vibrations in your production line and skewed products that are not presenting well to the coding technology can impact the overall quality of your mark.

Reviewing your material handling practices and making recommendations for the best use of your equipment is vital to achieving high quality marks on your products.

Verification and Validation

You can take your coding and labeling operation a step closer to guaranteed compliance by adopting a product verification or validation step after the mark has been applied to your product. There are several levels of verification that ensure that a mark:

has been successfully applied to the product
matches the mark that you requested be printed
is completely readable

Verification and validation require the use of scanners or vision systems as well as connectivity to your coding equipment and product databases.

Material Handling After Verification

When incorporating a verification or validation step into your coding and labeling operation, you will need some form of reactive material handling after verification takes place if a printed mark is considered to be illegible. When manufacturers encounter poor code quality, a signal can be triggered to stop the production line altogether to correct what is causing the poor print or a reject and redirect action can take place to separate the questionable product from the rest of production. If too many poor quality codes are encountered, production can be stopped to allow for a remedy.

Having issues with achieving packaging compliance and encountering too many marking mistakes? At Diagraph, we can help you quantify the true cost hitting your bottom line and will work with you to develop a game plan to minimize errors and ensure proper code adhesion.

Call us today at 800.722.1125 to learn more about how Diagraph partners with manufacturers to achieve product identification and packaging compliance success.

Is a Product Identification Site Audit Right for Your Facility?

Tue, 04 Sep 2018 16:03:22 GMT

If you haven’t had a top-to-bottom review of your coding and labeling operations within the past 5 to 10 years, you are probably overdue for a comprehensive product identification site audit. Technological advancements have allowed for manufacturers to achieve greater efficiencies and accuracy with their product coding efforts for all levels of packaging – from primary products all the way to pallet level labeling.

Diagraph can take the guess work out of coding and labeling operational best practices by offering free comprehensive site audits. We make a series of recommendations that span anywhere from making modifications to current equipment or practices for enhanced productivity to the complete retooling of your product identification operation to help you achieve your production and packaging compliance goals.

Our site audits include a close review of the following key areas:

Productivity and condition of existing equipment
- Is your equipment performing to its fullest capacity?
- Is your equipment a proper match for your product coding application/goals?
- Are there any modifications or maintenance actions that can be taken to achieve full-productivity?
- How much remaining useful life is estimated for each piece of equipment?
Proficiency of machine operators
- Are there any bottlenecks or workarounds regularly encountered by your team?
- Are there system features that are not being utilized that could improve efficiencies?
- Could your production team benefit from higher-level user training?
Maintenance team strategy
- Are your preventive maintenance intervals ideal for your manufacturing environment?
- Do you have everything you need to quickly overcome unexpected downtime?
- Could your maintenance team benefit from higher-level equipment maintenance training?

After reviewing these key areas and other aspects of your packaging compliance requirements, we provide a site audit report with simple recommendations that you can implement immediately as well as bigger picture recommendations that can be implemented overtime with planning and support. At Diagraph, our goal is to make it easy for our customers to achieve the perfect mark on their products. Regular site audits and account reviews are just one of the ways we work in partnership with our customers.

Call us today at 800.722.1125 to learn more about how Diagraph partners with manufacturers to achieve product identification and packaging compliance success.

Marking 125 Years in Business with Special Customer Savings at PACK EXPO International

Fri, 24 Aug 2018 15:23:26 GMT

2018 marks Diagraph’s 125^th anniversary in business and we’re inviting the industry to celebrate this momentous occasion with us at PACK EXPO International in Chicago. Diagraph is exhibiting at booth N-5721 with our full line-up of product solutions including small character inkjet, high-resolution inkjet case coders, all-electric labelers and thermal transfer overprinters. Come visit us and discover our new initiatives designed to make product identification easy for our customers. The show begins in Chicago on Sunday, October 14 and runs through Wednesday, October 17.

Visitors to have their badges scanned in the Diagraph booth will be eligible to take advantage of our exclusive show specials that run through the duration of 2018. Don't miss out on our best promotions of the year!

Linx 8900 Series Bundle Package

Buy a Linx 8900 Series small character continuous inkjet printer at more than 30% off and receive a free photocell and trolley stand. Over $4,000 in savings!

Why the Linx 8900 Series small character inkjet?

The hermetically sealed stainless steel printhead runs clean for up to 100 starts and stops
Self-service design with an all-in-one service module and guided on-screen instructions
Perfect for building a spare printer inventory with the longest extended shutdown interval in the industry

Double Your Print Area Deal

Get an Diagraph IJ768E ACS high resolution inkjet printhead for the price of the Diagraph IJ384E 2” printhead and double your available print height to accommodate larger, more complex case coding messages. Plus, when you purchase one day of installation and training, you’ll receive an extra day of installation and training at no charge.

Why the IJ768E high-resolution inkjet printheads?

Rugged design, stainless steel orifice plate protects electronics and printheads from shock, vibration and chemical contaminants
Repairable printheads last up to 10 years in the field
Double the available print area to accommodate larger, more complex messages

“All In” Labeling Deal

Buy any standard fullprint and apply labeler or tamp label applicator system and get all recommended accessories, installation and training for free.

Why the PA6000 print and apply labeler or LA4750 label applicator?

Auto-retract sensors recognize any variations in product height
Gentle tamp labeling onto each product limits the wear and tear of the actuator arm
Label present sensors tell the actuator arm to tamp gently onto each product only when label is fed from the roll, meaning no rework from missing labels
Comes with 3 recommended sensors, warning tower, adjustable T-base stand, discrete I/O

TTO Combo Deal

Buy one thermal transfer printer (excluding the MLi) and get a spare printhead and ribbon starter pack for free.

Why take advantage of this deal for your NGT Series or Allen XL5000 purchase?

Spare printhead for peace of mind
Complimentary ribbon to substrate matching service to build the starter ribbon pack for each system (6 rolls, must be formula we stock so a compatible match to all substrates is not guaranteed)

These offers are exclusive to visitors to the Diagraph booth N-5721 in PACK EXPO Chicago that have their badges scanned! Whether you are in need of an upgrade to your coding and labeling operations or looking to begin automating, this is a great opportunity to level-up your operational efficiencies for a great value.

Haven't registered to attend Pack Expo International yet? You can follow this link and use the 32K59 comp code to get free registration on Diagraph.

Sneak Peek at Diagraph's PACK EXPO Las Vegas Show Specials

Wed, 02 Aug 2017 13:25:46 GMT

Packaging and processing professionals from across the country will be in Las Vegas in September for PACK EXPO 2017 – and we hope that you’ll be one of them! Diagraph’s team will be at the show in Booth C-4010 showcasing our line-up of coding and labeling systems from continuous inkjet to all-electric labeling to thermal transfer overprinters and more. Stop by and we’ll show you why you can rely on the superior uptime performance of our printers so you can focus on what matters most to you – your product.

As an added value, those who visit Diagraph's PACK EXPO Booth C-4010 and have their badges scanned will be eligible to take advantage of our exclusive show specials that will run through the duration of 2017.

CIJ Linx 8900 | Best In Uptime Reliability

BUY ONE, GET ONE HALF OFF: Buy any Linx 8900 Series printer and get the second for half off!

The hermetically sealed stainless steel printhead runs clean for up to 100 starts and stops
Perfect for building a spare printer inventory with the longest extended shutdown interval in the industry

High-Resolution Large Character Inkjet | Industry's Longest-Lasting Printhead

DOUBLE YOUR PRINT AREA: Get an IJ768E 4" printhead for the price of the IJ384E 2" printhead.

Rugged design, stainless steel orifice plate protects electronics and printheads from shock, vibration and chemical contaminants
Repairable printheads last up to 10 years in the field
Double the available print area to accommodate larger, more complex messages

All-Electric Labeling | Most Intelligent Labelers

"ALL-IN" LABELING DEAL: Buy any standard full printer/applicator or standard tamp label/applicator system and get all recommended accessories and training for free.

Auto-retract sensors recognize any variations in product height
Gentle tamp labeling onto each product limits the wear and tear of the actuator arm
Label present sensors tell the actuator arm to tamp gently onto each product only when label is fed from the roll, meaning no rework from missing labels
Comes with 3 recommended sensors, warning tower, adjustable T-base stand, discrete I/O

Thermal Transfer Overprinters | Simplest Multi-Lane Integration

TTO COMBO DEAL: Buy one thermal transfer system (excluding the MLi) and get a spare printhead and ribbon starter pack for FREE.

Spare printhead for peace of mind
Complimentary ribbon to substrate matching service to build the starter ribbon pack for each system (6 rolls, must be formula we stock so a compatible match to all substrates is not guaranteed)

These offers are exclusive to visitors to the Diagraph booth C-4010 in PACK EXPO Las Vegas that have their badges scanned! You don’t want to miss out on these deals to upgrade your coding and labeling operations to more reliable, durable systems. Or, if you’re just starting out, this is a great opportunity to begin automating your coding operations.

We’ll see you in Vegas September 25-27!

Printing On All Four Sides Of Cases or Cartons

Mon, 04 Apr 2016 15:27:58 GMT

Common GS1 Barcodes Pictured Above. The following can be printed by Print and Apply Labeling and most High-Resolution Inkjet Technologies:
Barcodes: UPC-A, EAN-13, UPC-E, EAN-8, GS1 DataMatrix, GS1 QR Code, GS1-128, ITF-14
GTIN Types: GTIN-8, GTIN-12, GTIN-13, GTIN-14

Many major retailers and distribution centers require manufacturers to display important information on all four sides of cartons and cases that are intended for backroom storage purposes. This offers retailers ultimate flexibility for their inventory management programs.

The following information is important to effectively manage inventory:

Product Name and Other Identifiers
Machine Readable Barcode
Best By Date Code
Quantity
Handling/Storage Instructions
Lot/Batch Code

Having this information visible on your box is usually not enough. Manufacturers need to ensure that this important information is large enough and clear enough to read from a distance.

4-Side Print Solutions

Unfortunately, there are not any one-size-fits-all solutions to accomplish four-sided printing on cartons. Flexographic and lithographic pre-printed boxes are not practical for the important variable information needed with every shipment (i.e., best by date and lot/batch code). Manufacturers can turn to a combination of pre-printed information and print-on-demand information if flexographic elements are required. However, complete print-on-demand solutions offer manufacturers the greatest flexibility in terms of cost and supplies.

Print and Apply Labeling 4-Side Print Solutions

Because manufacturers have more options when choosing to use a labeling solution for their four-sided print requirements, the best solution for your particular operation depends largely on the speed of your line and your product throughput. The most efficient option in terms of the equipment required would be to opt for two opposing E-FASA (swing arm) print and apply labeling machines. One machine would apply the label to the front and the side of the box while the other would apply to the opposite side and the rear panel. This solution does not require a bump turn material handling mechanism.

The Diagraph PA/6000 with E-FASA tamp applicator module offers the greatest flexibility for manufacturers. The all-electric design frees the labeler from shop air, allowing it to be placed anywhere on the packaging line. Additionally, the servo motor and smart sensing technology unique to the PA/6000 system ensure that labels are precisely placed on time, every time.

If retailers and distribution centers require flexographic and lithographic printed barcodes, you can more easily manage pre-printed label stock than a large pre-printed box inventory. Utilize flexographic printed labels for all information that will remain the same and utilize the labeler’s printing capability to print the important variable information on demand. With that being stated, it is important to point out that printing barcodes using a wax-resin ribbon and a thermal print head onto consistent label stock is a highly reliable print method. The recommendation to get pre-printed label stock depends entirely on retailer requirements, but is not necessary if you want the print and apply labeler to handle your entire print message – including the barcodes.

Large Character Inkjet 4-Side Print Solutions

Many manufacturers can get away with only displaying information on one or two sides of a case. To accomplish print on two opposing sides, manufacturers need inkjet printers installed on opposite sides of the packaging line. At Diagraph, our high resolution large character inkjet system – Diagraph IJ4000 – can drive printheads on opposing sides of a single line from a single system. The unique centralized ink delivery system in the Diagraph IJ4000 allows floor operators to monitor and change fluids from a single location rather than having to monitor each individual print head.

Additional material handling is required when setting up your packaging line for four-sided printing. A “bump turn” material handling method is required to rotate the box 90° to present the remaining two panels for printing. Two additional opposing printheads need to be installed further down the line, positioned after the bump turn mechanism, to print on the remaining panels. Four-sided box printing can easily be accomplished using the Diagraph IJ4000 once the bump turn mechanism is in place on the packaging line. A single IJ4000 system can drive all four required printheads from a single system, allowing up to a 2” print height for the printed information.

Printing variable information using a Diagraph IJ384e printhead offering a maximum of 2” characters satisfies size requirements for most retailers. If larger characters or a larger print area is desired, manufacturers can opt for the Diagraph IJ768e printhead, which offers up to 4” of print height. A single Diagraph IJ4000 system can drive two IJ768e printheads, which means two systems would be required for a four-sided printing application. Many of our customers opt for the IJ768e 4” printhead to take advantage of the larger print area and future-proof for expanding retailer requirements.

The Diagraph IJ4000 system prints high resolution text, graphics and machine readable barcodes, including GTIN, ITF and GS1 varieties.

Additional Quality Assurance Measures

Both high resolution inkjet and print and apply labeling technologies can print machine readable barcodes with high quality resolution. Many of our customers install a fixed mount barcode imager to test the barcode quality. This information is sent to a PLC which reads the good or bad output from the barcode imager and stops the conveyor when a barcode gives a bad result. This extra quality measure ensures that only readable barcodes reach retailers.

Material Handling Solutions Provided by Diagraph

At Diagraph, we have customers large and small who have varying degrees of internal resources and packaging line expertise. We offer project management services for manufacturers who choose a Diagraph solution and need to outsource the material handling changes to their lines. Our dedicated engineers work closely with manufacturers to design a material handling solution that will meet their unique application need.

Still have questions about printing variable information on all four sides of a box? Contact us today to learn more about your options: Call 1-800-722-1125 or email info@diagraph.com.

Coding is a CRAFT | Top 3 Tips for Choosing a Coding Provider

Wed, 30 Mar 2016 18:57:42 GMT

Coding is a CRAFT

Top 3 Tips for Choosing a Coding Provider

It can be difficult to choose a marking, coding and labeling equipment provider with so many available. These tips will help you find the best provider for your business:

1. 1. Total Cost of Ownership (TCO) – This seems like an obvious consideration, but year after year manufacturing companies new to marking and coding make equipment purchases that cost them big over time. Ensure you understand your ongoing costs for equipment parts, consumables and service as well as downtime costs associated with routine maintenance before making a purchase. TCO varies widely from manufacturer to manufacturer.
1. 2. Ease of Use – Can your line operators easily change messages, refill fluids or labels and perform preventative maintenance with as little impact to uptime as possible? Equipment that is the easiest to use and most reliable features design elements that are engineered directly into the machines (as opposed to being applied after-market).
1. 3. Service Support Structure – Coding providers who are most responsive to your needs have field service operations dedicated to your neighborhood. Look for providers that offer telephone support and have layers of expertise available within the organization to ensure that your unique application gets every consideration necessary.

At Diagraph, we are dedicated in solving your coding and labeling challenges. Diagraph has been assisting customers for over 120 years improving production line efficiencies with simple, reliable, cost-effective coding and labeling solutions. Visit us at www.diagraph.com or contact us at 800.722.1125.

The Art of Automatic Label Dispensing

Wed, 27 Jan 2016 19:26:53 GMT

The Art of Automatic Label Dispensing

By Steve Dods, Product Manager

Automated Labeling Products (ALP) and Thermal Transfer Overprinter (TTO)

The Art of Automatic Label Dispensing:

· The amount of release agent (silicone coating) applied to the paper portion of the liner substrate

· The aggressiveness of the adhesive being used for the label, usually determined by the application need

· The angle of the peel blade

· The tension that is developed on the opposing sides of the peel blade

· The addition of an air knife or pressurized flow of air to force a separation between the label and the liner at the peel point

· The depth of the die-cut (the cutting process of forming the label within the continuous adhesive top sheet)

· The age of the materials and storage conditions

When these factors are not within the bounds of system acceptability, the possible results are:

· The label does not separate from the liner at all, and follows the liner over the peel blade. No label is separated. Extreme case.

· The label begins to peel, but the angle of separation changes (due to adhesive aggressiveness/lack of tension/not enough release agent) and the label does not feed out to the designated retaining surface for application

· The label peels out to the retaining surface for automated application, but the trailing edge is still connected to the edge of the liner. Upon application, the label hinges or rotates about this edge, and is ultimately not applied to the product

Two views of labels hinging onto the liner after traversing the peel blade edge. The labels remain attached to the liner.

Problems with the Current Solutions:

· Alternate designs will use an air knife and air pressure to separate the label from the liner. This creates a potential issue of blowing the label off of the tamp pad and into the air, since the amount of pressure is constant and the bond resistance varies from label to label. No label applied to product.

· Alternate designs will allow the label to feed out to the tamp pad, and then use articulation to move away from the peel edge. This results in extra moving parts and more failure points. This method does not solve other aspects of peeling, such as label face stocks with increased friction and drag resistance.

The Solution:

To solve the issues of dispensing labels with the aforementioned attributes, the system was modified to perform a vibrating function by way of the preexisting brushless dc actuator motor. Since the heart of the All-Electric labeling system design is based on a proprietary circuit design and control algorithm, changes could be instituted to allow the surface of the tamp pad (the holding plate for the label prior to application) to vibrate during the feed of the label. The vibration effect is only active after the feed of the label, which breaks the adhesive fiber bonds that would normally be maintained between label and liner without this technology. By vibrating in the low Hertz range, the system can separate labels that would otherwise hinge and cause label jams or cause the label to avoid being applied with adhesive side facing the product. This patented method of ensuring the labels are freed from the liner is known as VibraFeed.

Innovation Benefits:

· Automatically separates the label adhesive fiber bonds with the liner without increasing the process time

· Uses inherent components of the system that are normally tasked with the application of the label to the product

· Increases the range of label material quality that can be used for automatic application

At Diagraph, we are dedicated in solving your coding and labeling challenges. Diagraph has been assisting customers for over 120 years improving production line efficiencies with simple, reliable, cost-effective coding and labeling solutions. Contact us to learn more about the Automated Label Applicators product line. Visit us at www.diagraph.com or contact us at 800.722.1125.

Comparing Pneumatic and Electric Label Printer Applicators

Fri, 11 Dec 2015 20:57:15 GMT

Diagraph’s E-Series labelers are considered the simplest, most reliable all-electric labeling solutions in the industry today thanks to years of continuous improvement and innovation. Our entire line up of Diagraph E-Series print and apply and automated label applicator systems build upon the durability of the proven Diagraph Platinum Series design, yet incorporate key electronic enhancements that allow it to perform more consistently and reliably over time. The result? A simpler, more reliable labeler that can do everything a pneumatic system can do, only better.

It’s all in the design:

The high velocity vacuum fan offers greater reliability than pneumatic air

Our high velocity vacuum fan design allows for full surface area control of the label across the entirety of the pad, achieving a uniform label transfer from pad to product. This consistently performs better than pneumatic designs that feature just a few pneumatic vacuum hole locations on the pad. Diagraph’s high velocity vacuum fan design eliminates the easily clogged small orifices found with pneumatic systems, allowing our labelers to perform more reliably in dusty environments.

The electronically controlled actuator arm movement guarantees precision label placement over time, every time

Our electronically controlled actuator arm allows you to digitally set the application speed to ensure repeatable and reliable operation. Thanks to Diagraph’s all-electric SERVO motor driven design, you are no longer at the mercy of the questionable consistency and reliability of your plant air. Our electronic controls eliminate the need for manual adjustments to address system age and wear.

The color touchscreen display puts more of the information you need right at your fingertips

The E-Series user interface features a larger display that enables you to view more system settings and system health information all at once. This larger, simplified display allows for fewer menus and less toggling between screens. You can now get to the system settings you need with fewer touches.

These are just a few of the many advantages of our E-Series labeling solutions. Contact us today to learn more about how trading up to our E-Series labelers can help save you time, money and the hassle of mislabeled products, cases, traypacks and pallets.

Reason Manufacturers Moving From Automated Air Labelers

Thu, 19 Nov 2015 14:45:10 GMT

Plant managers and maintenance managers alike are deserting pneumatically driven label applicators in favor of all-electric label applicators for one BIG reason – dirty air lines.

Unpredictable, unfiltered air supplies disrupt the efficiency and performance of air supported tools and machinery, especially label applicators. Water, oil and particulate matter are hard on label applicators, impeding the performance and reliability of the tamp pad suction and the actuator arm – the key functionality of any automated labeling machine!

Although clogged air is the number one reason for choosing all-electric solutions, there are a number of benefits that air label applicators just can’t match:

Precision label handling across the entirety of the pad throughout transit
- Superior suction made possible by larger vacuum passages prevents the routine clogging experienced in real-world manufacturing environments
- Smart auto-retract sensors combined with a digital delay setting allow for superior control of impact force and maximum label adhesion upon contact
Electric SERVO motors and smart auto-retract sensors combine to achieve more precise movements, automatically compensating for changes in box sizes and distances without adjustments
No need to compromise on line speeds
No need to compromise on label sizes
Portable! No air line means you can plug in and run the label applicator anywhere
Saves energy consumption and saves money! All-electric labelers cost up to 50 - 90% less to run when compared to pneumatically driven systems

With all of this being said, not all electric label applicators are created equal! Contact us today to learn why Diagraph printer-applicators and label applicators lead the industry in both reliability and performance.

Choosing the Right Label Adhesive -- A Comparison

Wed, 26 Aug 2015 14:25:52 GMT

By Steve Dods, Automated Labeling Products (ALP) and Thermal Transfer Overprinter (TTO) Products Manager

Have you ever purchased an item from the store, and later at home wondered why they used a label that doesn't easily come off of your new item? Have you seen labels that are hardly attached to the side of an item at Home Depot and wonder how many of those labels never even made the trip to the destination store? Well, you are not alone, sadly, and the better question is how much is that adding cost in the supply chain or turning off customers? Now that sticker wisdom can be found in a simple table below:

BEST (ADHESIVE) PRACTICES FOR STICKERS (WE CALL THEM LABELS!)
Adhesive Type	Purpose	What to Know	Where Used
All-Temp	Multi-purpose adhesive Most common Good initial tack Strong long term bond	Best on room temperature products Not easily removed Cost effective	Corrugated Cases *Pallets* *Primary product marketing label*
Cold-Temp	Designed to bond to refrigerated products	Label must be room-temp to have activate adhesive - product will be cold Label will be a heavier weight - may require additional labeler system set up specifics Label rolls should be stored at room temperature - heating device needed on label roll in point of use area	Refrigerated products, such as ice cream containers, dairy, meat processed cases
Wet-Stick	Designed with adhesive that compensates for wet surfaces	Air-knives to clear as much water as possible recommended Full label apply pressure is required to allow the adhesive to operate correctly - direct contact, not blow methods, required here for auto apply	*Bottling / Jars*
Tire Adhesive	Surfaces that contain voids, may be dusty, and have curvature	Very heavy adhesive that generally does not do well with paper label substrates Synthetic label materials generally used	*Tires*
Removable	Can be removed from some surfaces	Very important to test target products for initial and long term adhesion	*Consumer goods*
Ultra-Removable	Can be removed from most surfaces, even after long term bonding	Great for label on glass screens, plastics, metals, and other end consumer products where the label is only informational	*Electronic Products, Medical*
Soak and Remove	Adhesive is designed for water solubility	Used in track and trace applications for reusable totes and containers	*Fruit, vegetable, and nut case-level packaging*

Learn more about automated labeling technology and the benefits of all-electric machines versus pneumatic.

Looking to Increase Productivity?

Thu, 11 Jun 2015 16:07:45 GMT

Looking to Increase Productivity?

ITW Shakeproof is the first established ITW (Illinois Tool Works) division. They bring over 80 years of expertise as a manufacturer and innovator of the twisted-tooth lock washer, which paved the way for fastener application engineering. This method of engineering remains popular to this day.

ITW Shakeproof needed to find a method for increasing productivity while reducing packaging line concerns regarding safety. They transitioned away from manually applying labels that were pressure-sensitive and looked for options to automate this process. Manufacturing Engineer, Robert Bauer, saw the need to upgrade the current packaging line in order to make this happen.

They were knowledgeable about Diagraph’s coding and labeling equipment, and decided to add a second line and mirror the equipment on the two lines. Each line featured one PA/6000 label printer/applicator and an IV large-character inkjet coder. The PA/6000 has the capabilities to print the bar code, part number, lot code and company specific information in multiple text sizes all on a 4X6 p-s label. The IV coder marks customer identification information in green ink right on to the other side of every case.

After establishing the two lines, ITW Shakeproof incorporated a robotic palletizer from Fanuc Robotics to save on manual labor. By implementing the two lines and the addition of the palletizer, not only were costs lowered, but employee safety was enhanced. Employees no longer manually lifted heavy cases or stood in one position for hours at a time. Within one year, they saved 331 hours in overtime and eliminated back injuries caused by case lifting.

Need to automate your line? Visit www.diagraph.com for more information on our coding and labeling solutions.

Diagraph's Blog

Avoid Labeling Mistakes by Removing Plant Air

Gain precision and accuracy through applicator control

Maintain precision and accuracy through label control

Protect your liner and protect your uptime

Smart Sensors Gives Automated Print‐And‐Apply Systems a Big Advantage

Focus on Pallet Labeling Workflows to Maximize Efficiency

How do I get labels to stick in hot and humid environments?

Common Issues with Labels in High Temperature Environments

Best Practices for Label Storage in Extreme Temperatures

Understand Labeling from the System to the Consumables

Superior labeling power source — pneumatic air/electric labeling

Increase contract packaging productivity by minimizing equipment interventions

Designing Coding and Labeling Equipment to Last

Setting People Up for Success

Partnering to Develop a Game Plan

How to Pick the Best Product Identification Solution

Print Message Requirements

Application Requirements

Available Product Identification Solutions

Message Validation

Levels of Message Validation

Your Guide To Automating Your Pallet Labeling Process

Key Considerations for Assessing Coding Equipment Uptime

Length of time between consumable replenishment

Streamlining consumable replenishment

Preventive Maintenance Service Intervals

How to Reduce Marking Mistakes and Ensure Proper Code Adhesion

Coding Technology

Ink, Label, Ribbon Match

Material Handling Before Product Coding

Verification and Validation

Material Handling After Verification

Is a Product Identification Site Audit Right for Your Facility?

Productivity and condition of existing equipment

Proficiency of machine operators

Maintenance team strategy

Marking 125 Years in Business with Special Customer Savings at PACK EXPO International

Linx 8900 Series Bundle Package

Double Your Print Area Deal

“All In” Labeling Deal

TTO Combo Deal

Haven't registered to attend Pack Expo International yet? You can follow this link and use the 32K59 comp code to get free registration on Diagraph.

Sneak Peek at Diagraph's PACK EXPO Las Vegas Show Specials

CIJ Linx 8900 | Best In Uptime Reliability

High-Resolution Large Character Inkjet | Industry's Longest-Lasting Printhead

All-Electric Labeling | Most Intelligent Labelers

Thermal Transfer Overprinters | Simplest Multi-Lane Integration

Printing On All Four Sides Of Cases or Cartons

Coding is a CRAFT | Top 3 Tips for Choosing a Coding Provider

The Art of Automatic Label Dispensing

Comparing Pneumatic and Electric Label Printer Applicators

Reason Manufacturers Moving From Automated Air Labelers

Choosing the Right Label Adhesive -- A Comparison

BEST (ADHESIVE) PRACTICES FOR STICKERS (WE CALL THEM LABELS!)

Looking to Increase Productivity?