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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!
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.
All-Electric Labeller Utilizes Smart Sensing Technology to Maximize Reliability
Diagraph recently launched the LA/4750 – a servomotor-controlled label applicator system featuring enhanced smart sensing technology. The intuitive design allows the LA/4750 to auto-detect irregularities in operation, reducing complications from missing labels, variable line speeds and inconsistent product distances – resulting in the industry’s smartest, most reliable all-electric label applicator.
The new label applicator system builds upon Diagraph’s proven Platinum E-Series labelling technology to offer greater total-system reliability. Utilizing precision control made possible by high performance brushless DC servomotors, the LA/4750 reads smart sensor signals in real-time to adjust label dispensing commands. Diagraph’s smart sensing technology ensures precision label placement, reducing the need to rework improperly labelled products.
The LA/4750 features key enhancements that allow it to accurately dispense hard-to-read clear labels, prevent missed products and double feeds, and auto-adjust outputs to changes in line speeds. The system also features an independent rewind drive that works as a clutch-less, no adjustment system that is easy to web – a major pain point with other labelling machines.
Available in wipe and tamp models, the LA/4750 can apply labels to the side, top, bottom and corner-wrap of primary products and cases. Diagraph’s all-electric labelling technology allows manufacturers to move away from expensive, dirty and unreliable pneumatic air without compromising performance.
The LA/4750 is designed to be simple to set up and easy to use. For more information, call 800-722-1125 or visit diagraph.com.
There is a great debate in the packaging technology industry around the core driver of automated labeling equipment. Which is a superior labeling power source — pneumatic air or electric? Pneumatic labeling systems are built around timing-based commands that drive label movements based 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 that 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, 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 servomotors 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 more than 120 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.
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.
2018 marks Diagraph’s 125th 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!
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?
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?
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?
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?
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.
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:
To understand system uptime better, let’s take a closer look at each of these key areas:
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.
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.
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.