Label web removal apparatus and corresponding method

Abstract

The invention relates to an apparatus (10) for removing a label web (15) from a continuous sheet (12), and a method (40) of operation thereof. The continuous sheet (12) comprises a substrate web (13) and the label web (15). The apparatus (10) comprises a cross-cut device (18) to impart a cross-cut on a full width of the label web (15), a dispensing blade (23) being movable between a deployed position and a retracted position, and a label web removal device (26). The apparatus (10) is adapted to receive the continuous sheet (12) into the apparatus, the dispensing blade (23) is operable to the deployed position to cooperate with the continuous sheet (12) prior to the cross-cut reaching the dispensing blade (23) to dispense the label web (15) from the substrate web (13). The label web removal device (26) being operable to receive the label web (15) and to draw the label web (15) from the substrate web (13).

Description

[0001] Label Web Removal Apparatus

[0002] Technical Field

[0003] The invention relates to an apparatus for removing a label web from a continuous sheet, and a method of operation thereof.

[0004] Background

[0005] It is known to provide an apparatus to create self-adhesive labels from a continuous sheet of material comprising a substrate web and a label web. Such an apparatus typically has a rotatable tool cylinder with a tool plate mounted thereon, and an anvil cylinder adjacent to the tool cylinder. The continuous sheet passes between the anvil cylinder and the tool cylinder, and the labels are cut into the label web of the continuous sheet.

[0006] A waste label web (known as a “matrix”) remains on the substrate web, and typically comprises about 3mm that is left around each label after the label cutting process. After the label cutting process, the matrix is required to be removed from the continuous sheet so that the labels remain on the substrate web. The labels can subsequently be applied to products (e.g. bottles) as required. Typically, the labels are dispensed from the continuous sheet of material by running the continuous sheet over an edge on a rear side thereof (i.e. the substrate web side) so that the labels peel away from the substrate web onto the bottles.

[0007] It is known to manually wind the waste label web onto a carboard tube known as a core, which requires the apparatus to be stopped so that it can be fed onto the cardboard tube. When the carboard tube of the waste label material (i.e. the matrix) has reached a maximum size the apparatus must also be stopped. Such stopping of the apparatus is disadvantageous and wastes time. Furthermore, the tube of waste matrix material is typically very bulky comprising about 10% material and 90% air, and is expensive to dispose of due to the low density.

[0008] It is also known to remove the waste label web using a blade to scrape it from the substrate web. The waste material typically folds onto itself in a concertina manner and falls into a waste bin. Such a technique has the problem that it may not always be effective because the blade may become blocked with adhesive from the waste label web, and the waste material may not fold onto itself in a consistent manner. The folded waste material is also bulky and not very compact. Furthermore, the blade may wear out quickly and require replacement.

[0009] It is broadly an object of the present invention to address one or more of the above mentioned disadvantages.

[0010] Summary

[0011] What is required is an apparatus which may reduce or minimise at least some of the above-mentioned problems.

[0012] According to a first aspect of the invention, there is provided an apparatus for removing a label web from a continuous sheet comprising a substrate web and the label web, the apparatus comprising a cross-cut device to impart a cross-cut on a full width of the label web, a dispensing blade being movable between a deployed position and a retracted position, and a label web removal device, the apparatus being adapted to receive the continuous sheet into the apparatus, the dispensing blade being operable to the deployed position to cooperate with the continuous sheet prior to the cross-cut reaching the dispensing blade during operation of the apparatus to dispense the label web from the substrate web, wherein the label web removal device is operable to receive the label web and to draw the label web from the substrate web.

[0013] Such an apparatus provides the advantage that the label web can be removed from the substrate web in a continuously process. It will be appreciated that the label web may be a complete and intact label web, or a waste label web (i.e. a “matrix”). Furthermore, in the deployed position the dispensing blade cooperates with the continuous sheet on the substrate web side thereof. The cross-cut device imparts the cross-cut on the label web only, and when the label web has peeled away from the substrate web (i.e. due to the continuous sheet being run over the dispensing blade) the label web removal device operates to pull the label web away from the substrate web in a continuous process. Such an arrangement does not require the apparatus to be stopped. Furthermore, the label web is drawn from the substrate web in a consistent and clean manner, and the adhesive from the label web is less likely to block the apparatus or slow the label web removal process.

[0014] Preferably the label web removal device comprises a pair of label web feed rollers to receive the label web therebetween. Preferably at least one of the label web feed rollers being a drive roller.

[0015] Preferably one of the rollers is fixed, and the other roller is movable. Such an arrangement provides for different modes of operation of the apparatus.

[0016] Preferably the movable roller is the drive roller that is operable to receive the label web such that a sticky surface of the label web is operable to contact the movable roller and is wound thereon to draw it from the substrate web. The movable roller may be provided with a sleeve, the sticky surface of the label web being arranged to contact the sleeve and be wound thereon, the sleeve being removable from the movable roller for disposal of the label web.

[0017] In one arrangement the movable roller is translatable as the label web is wound thereon.

[0018] Preferably the pair of label web feed rollers, or the sleeve and one of the label web feed rollers, are in contact with one another prior to receiving the label web. Such an arrangement assists with trapping the label web between the label web feed rollers to draw is from the substrate web.

[0019] In another arrangement a duct is provided with a flow of air via a partial vacuum, the duct having an inlet being operable to receive the label web and to draw it from the substrate web. Preferably a gap is provided between the pair of label web feed rollers prior to receiving the label web. Preferably the gap is between 5mm and 20mm, and preferably 10mm. Such a gap may avoid or reduce the possibility of the label web sticking to one of the label web feed rollers.

[0020] Preferably one of the label web feed rollers is at an inlet opening of the duct such that a curtain of air is drawn around said label web feed roller. Preferably the duct is close fitting with an end of said label web feed roller. Preferably said label web feed roller is the drive roller.

[0021] Preferably said label web feed roller is provided with a non-stick surface. Preferably said label web feed roller is provided with a sleeve having the non-stick surface. Preferably an inner surface of the duct has a non-stick inner surface. Preferably the nonstick inner surface is provided on at least a portion of the inlet of the duct. Such arrangements may avoid or reduce the possibility of the label web sticking to one of the label web feed rollers and / or the duct.

[0022] Preferably the dispensing blade is movable back to the retracted position and the label web continues to be dispensed from the substrate web during operation of the apparatus. Moving the dispensing blade back to the retracted position has the advantage that the continuous sheet has one less surface over which to run, which may allow an increased speed for the continuous sheet and stripping of the label web from the substrate web. Preferably the apparatus further comprises a label web advance device being moveable between a deployed position and a retracted position, wherein the label web advance device is operable to the deployed position to advance the continuous sheet prior to the dispensing blade being moveable to the deployed position.

[0023] In one embodiment the apparatus further comprises a label web drive roller, wherein the label web advance device is operable to the retracted position to at least partially wrap the label web around the label web drive roller. Such an arrangement provides the advantage of driving and controlling a tension of the label web as it is drawn from the substrate web.

[0024] Preferably the label web advance device is a label web advance arm that is pivotable about one end thereof. Preferably the label web advance device has one or more rollers thereon. Such aspects provide a convenient configuration for of the label web advance device, and provides a ready way to control movement the substrate web and the label web.

[0025] Preferably the cross-cut device comprises a pair of cross-cut rollers, one of the cross-cut rollers having at least one blade. Such an arrangement provides a ready way to impact the cross-cut into the label web.

[0026] Preferably the blade is at an angle of between 80 to 89 degrees to the direction of travel of the continuous sheet. Preferably the angle is between 85 to 89 degrees to the direction of travel of the continuous sheet. Preferably the angle is substantially 87.5 degrees to the direction of travel of the continuous sheet. Such an angle for the blade reduces the pressure required to produce the cross-cut in the label web.

[0027] Preferably the blade comprises one of up to six or more cutting blades that are mounted on a cutting plate of one of the cross-cut rollers, each cutting blade being of a different height on the surface of the cutting plate. Such a cutting plate can be used for different thicknesses of the label web.

[0028] Preferably the dispensing blade is mounted on a dispensing arm that is pivotable about one end thereof. Such an arrangement provides a convenient configuration for of the dispensing blade.

[0029] Preferably the dispensing arm has a contact roller for contact with the substrate web of the continuous sheet prior to the dispensing blade moving to the deployed position to cooperate with the continuous sheet. Preferably the continuous sheet is between the contact roller and one of the label web feed rollers prior to the dispensing blade moving to the deployed position.

[0030] Preferably the apparatus further comprising a granulator to receive the label web from the label web removal device and to cut the label web into granules. Such a granulator cuts the label web into small pieces for subsequent processing.

[0031] Preferably an air feed device is provided between the label web removal device and the granulator, and is operable to direct at least one jet of air onto the label web to guide it into the granulator. Preferably the air feed device is operable to direct a first jet of air on one side of the label web, and a second jet of air on the other side of the label web. Preferably each jet of air comprises a curtain of air that is substantially across a full width of the label web. Such an air feed device assists with guiding the label web into the granulator and also helps to keep cut pieces of the label web in the granulator.

[0032] Preferably the apparatus further includes a compactor to receive and compress the granules from the granulator. The compactor reduces the volume of the waste label web so that it can be subsequently disposed of at a reduced cost.

[0033] Preferably at least one tracking device is provided for monitoring the continuous sheet within the apparatus and to determine the position of the cross-cut. Preferably the continuous sheet has a plurality of markers thereon, and the tracking device comprises at least one sensor device being operable to detect the markers to determine the position of the cross-cut. Preferably the tracking device comprises at least one roller of the apparatus to determine the position of the cross-cut. Such arrangements provide for ready monitoring of the continuous sheet as it moves through the apparatus.

[0034] According to another aspect of the invention there is provided a method of operating an apparatus according to the first aspect of the invention for removing a label web from a continuous sheet comprising a substrate web and the label web.

[0035] According to another aspect of the invention there is provided a method of removing a label web from a continuous sheet using an apparatus comprising a cross-cut device, a dispensing blade that is moveable between a deployed position and a retracted position, and a label web removal device, the continuous sheet comprising a substrate web and the label web, the method including: receiving the continuous sheet into the apparatus; cutting the label web across a width thereof using the cross-cut device; moving the dispensing blade to the deployed position to cooperate with the continuous sheet prior to the cross-cut reaching the dispensing blade to dispense the label web from the substrate web; and receiving the label web at the label web removal device to draw the label web from the substrate web.

[0036] Such a method provides the advantage that the label web can be removed from the substrate web in a continuously process. It will be appreciated that the label web may be a complete and intact label web, or a waste label web (i.e. a “matrix”). Furthermore, in the deployed position the dispensing blade cooperates with the continuous sheet on the substrate web side thereof. The cross-cut device imparts the cross-cut on the label web only, and when the label web has peeled away from the substrate web (i.e. due to the continuous sheet being run over the dispensing blade) the a label web removal device operates to pull the label web away from the substrate web in a continuous process. Such an arrangement does not require the apparatus to be stopped. Furthermore, the label web is drawn from the substrate web in a consistent and clean manner, and the adhesive from the label web is less likely to block the apparatus or slow the method of label web removal. Preferably the label web removal device comprises a pair of label web feed rollers to receive the label web therebetween, the method including drawing the label web from the substrate web using the pair of label web feed rollers.

[0037] Preferably at least one of the label web feed rollers is a drive roller, the method including drawing the label web from the substrate web using the drive roller.

[0038] Preferably one of the rollers is fixed, and the other roller is movable, and wherein the movable roller is the drive roller, the method including receiving the label web on the movable roller so that a sticky surface of the label web contacts the movable roller and is wound thereon to draw it from the substrate web.

[0039] Preferably the movable roller is provided with a sleeve, the method including the sticky surface of the label web contacting the sleeve so that it is wound thereon, and removing the sleeve from the movable roller for disposal of the label web.

[0040] In one arrangement the movable roller is translatable, the method including translational movement of the movable roller as the label web is wound thereon.

[0041] In one arrangement the apparatus further includes a duct with an inlet, the method including providing the duct with a flow of air via a partial vacuum, and receiving the label web at the inlet to draw it from the substrate web. Preferably a gap is provided between the pair of label web feed rollers, the method including setting the gap prior to receiving the label web.

[0042] Preferably one of the label web feed rollers is at an inlet opening of the duct, the method including drawing a curtain of air around said label web feed roller.

[0043] Preferably the method further includes moving the dispensing blade back to the retracted position so that the label web continues to be dispensed from the substrate web. Moving the dispensing blade back to the retracted position has the advantage that the continuous sheet has one less surface over which to run, which may allow an increased speed for the continuous sheet and stripping of the label web from the substrate web.

[0044] Preferably the apparatus further comprising a label web advance device moveable between a deployed position and a retracted position, the method including moving the label web advance device to the deployed position to advance the continuous sheet prior to the dispensing blade being moveable to the deployed position.

[0045] Preferably the apparatus further comprising a label web drive roller, the method including moving the label web advance device to the retracted position to at least partially wrap the label web around the label web drive roller. Such an arrangement provides the advantage of driving and controlling a tension of the label web as it is drawn from the substrate web. Preferably the method further includes using the cross-cut device to cut the label web at an angle of between 80 to 89 degrees to the direction of travel of the continuous sheet. Preferably the method further includes using the cross-cut device to cut the label web at an angle of between 85 to 89 degrees to the direction of travel of the continuous sheet. Preferably the method further includes using the cross-cut device to cut the label web at an angle of substantially 87.5 degrees to the direction of travel of the continuous sheet. Such an angle for the blade reduces the pressure required to produce the cross-cut in the label web.

[0046] Preferably the dispensing blade is mounted on a dispensing arm that is pivotable about one end thereof, the dispensing arm having a contact roller, the method further including contacting the substrate web of the continuous sheet with the contact roller prior to the dispensing blade moving to the deployed position.

[0047] Preferably the method includes locating the continuous sheet between the contact roller and one of the label web feed rollers prior to the dispensing blade moving to the deployed position.

[0048] Preferably the method further includes using a granulator to receive the label web from the label web removal device, and cutting the label web into granules using the granulator. Such a granulator cuts the label web into small pieces for subsequent processing. Preferably the method further includes using an air feed device between the label web removal device and the granulator to direct at least one jet of air onto the label web to guide it into the granulator. Such an air feed device assists with guiding the label web into the granulator and also helps to keep cut pieces of the label web in the granulator.

[0049] Preferably the method further includes using a compactor to receive and compress the granules from the granulator. The compactor reduces the volume of the waste label web so that it can be subsequently disposed of at a reduced cost.

[0050] According to an alternative characterisation of the invention there is provided an apparatus for removing a label web from a continuous sheet comprising a substrate web and the label web, the apparatus comprising a cross-cut device to impart a cross-cut on a full width of the label web, a dispensing blade, and a label web removal device, the apparatus being adapted to receive the continuous sheet into the apparatus, the dispensing blade being operable to a position to cooperate with the continuous sheet prior to the cross-cut reaching the dispensing blade during operation of the apparatus to dispense the label web from the substrate web, wherein the label web removal device is operable to receive the label web and to draw the label web from the substrate web.

[0051] According to an alternative characterisation of the invention there is provided a method of removing a label web from a continuous sheet using an apparatus comprising a crosscut device, a dispensing blade, and a label web removal device, the continuous sheet comprising a substrate web and the label web, the method including: receiving the continuous sheet into the apparatus; cutting the label web across a width thereof using the cross-cut device; moving the dispensing blade to cooperate with the continuous sheet prior to the cross-cut reaching the dispensing blade to dispense the label web from the substrate web; and receiving the label web at the label web removal device to draw the label web from the substrate web.

[0052] According to an alternative characterisation of the invention there is provided a method of removing a label web from a continuous the method including: receiving the continuous sheet into an apparatus; cutting the label web across a width thereof; moving a dispensing blade into the continuous sheet prior to the cut across the width of the label web to dispense the label web from the substrate web; and drawing the label web away from the substrate web.

[0053] Any preferred or optional features of one aspect or characterisation of the invention may be a preferred or optional feature of other aspects or characterisations of the invention.

[0054] Brief Description of the Drawings

[0055] Other features of the invention will be apparent from the following description of preferred embodiments shown by way of example only with reference to the accompanying drawings, in which;

[0056] Figure 1 shows a side view of a label web removal apparatus according to an embodiment of the invention; Figure 2 shows a view of a part of the apparatus shown in Figure 1 in a starting condition;

[0057] Figure 3 shows a view the apparatus shown in Figure 2 in a web advance condition;

[0058] Figure 4 shows a view of the apparatus shown in Figure 2 in a dispense arm advance condition;

[0059] Figure 5 shows a view of the apparatus shown in Figure 2 in a dispense arm retraction condition;

[0060] Figure 6 shows a view of the apparatus shown in Figure 2 with a label web advance arm in a retracted condition;

[0061] Figure 7 shows a side view of an air feed device of the apparatus of Figures 1 to 6 according to an embodiment of the invention;

[0062] Figure 8 shows steps of a method according to an embodiment of the invention;

[0063] Figure 9 shows a side view of a label web removal apparatus according to another embodiment of the invention;

[0064] Figure 10 shows a view of a part of the apparatus shown in Figure 9 in a starting condition;

[0065] Figure 11 shows a view the apparatus shown in Figure 10 in a partial web advance condition;

[0066] Figure 12 shows a view of the apparatus shown in Figure 10 in a label web dispense condition;

[0067] Figure 13 shows a side view of a label web removal apparatus according to another embodiment of the invention; Figure 14 shows a view of a part of the apparatus shown in Figure 13 in a starting condition;

[0068] Figure 15 shows a view the apparatus shown in Figure 14 in a partial web advance condition; and

[0069] Figure 16 shows a view of the apparatus shown in Figure 14 in a label web dispense condition.

[0070] Detailed Description

[0071] Figure 1 shows a side view of a label web removal apparatus according to an embodiment of the invention, generally designated 10. The label web removal apparatus 10 may alternatively be termed a matrix removal apparatus. In Figure 1 a continuous sheet of material 12 is shown with a dashed line as it passes through the apparatus 10, and the direction of travel through the apparatus is shown with an arrow on the dashed line. The continuous sheet 12 comprising a substrate web 13 and a label web 15 (see Figures 5 and 6).

[0072] As shown in Figure 1, the apparatus 10 has an infeed drive roller 14 to feed the continuous sheet 12 into the apparatus 10. The continuous sheet 12 then passes on to an edge trim device 16 to trim the substrate web 13 to the correct width so that it readily passes through the apparatus 10. The continuous sheet 12 then passes through two cross-cut rollers 18 where one of the rollers has a cutting plate with a blade. The blade may be at 90 degrees to the direction of travel of the continuous sheet 12. The blade may also be at an angle slightly away from 90 degrees to the direction of travel of the continuous sheet 12, for example 80 to 89 degrees, or 85 to 89 degrees, or more preferably substantially 87.5 degrees. The cross-cut rollers 18 create a cut through a full width of the label web 15 only, which may be about 0.1mm thick. Providing the blade at a slight angle reduces the force required to produce the cross-cut in the label web 15 so that the cross-cut on the width of the label web 15 is over about 10mm in length in the direction of travel of the continuous sheet 12. The cutting plate may have up to six or more blades for different thicknesses of the label web 15. Each of the six or more blades being on the cutting plate and having a different height on the surface of the cutting plate.

[0073] The continuous sheet 12 then passes on to a dispense arm 20, a label web drive roller 22, and a label web advance arm 24. The dispense arm 20 has a dispensing beak 23, which impinges on a full width of the continuous sheet 12 to dispense label web 15 as discussed below. The dispensing beak 23 may alternatively be termed a dispensing blade, and may be made of suitably wear-resistant material that also dissipates heat from friction such as steel having a high carbon content (i.e. high tensile steel), or carbon fibre reinforced plastic. An edge of the dispensing beak 23 has a radius of about 1mm, which reduces the chances of cutting the substrate web 13. The radius of the edge maybe in the range 0.5mm to 3mm. It will be appreciated that in Figure 1 the dispensing arm 20 and the label web advance arm 24 are shown in an open position (i.e. a retracted condition). The label web advance arm 24 may be alternatively termed the label web advance device. The label web advance arm 24 is operated after dispensing of the label web 15 to wrap it onto label web drive roller 22, and the label web drive roller 22 drives and controls the tension of the label web 15, as shown below with reference to Figures 3 to 6. In one arrangement the label web drive roller 22 may have a textured surface (i.e. a knurled surface or a patterned surface) to provide additional grip to the label web 15.

[0074] Also shown in Figure 1 are two label web feed rollers 26, which are a pair of rollers to feed the label web 15 into a granulator 28. The label web feed rollers 26 may be alternatively termed label web rollers 26, and are in contact with one another or nearly in contact with one another to grip and feed the label web 15 into the granulator 28. The granulator 28 is a rotary knife to cut the label web 15 into small pieces or granules, which may be less than 1mm2. A compactor 30 then receives and compacts the cut label web 15. The compactor is a screw compactor device to compress the cut pieces of the label web 15 to reduce wasted space and make the waste material more readily manageable. In another embodiment the label web feed rollers 26 may be alternatively termed a label web removal device, and my not necessarily be rollers.

[0075] Figure 2 shows a view of a part of the apparatus shown in Figure 1 in a starting condition. In Figure 2 like features to the arrangements of Figure 1 are shown with like reference numerals. In Figure 2 the path of the continuous sheet 12 is shown before the label web 15 is dispensed from the continuous sheet 12. The dispensing arm 20 and the label web advance arm 24 are shown in an open position where the continuous sheet 12 is not in contact with the label web drive roller 22 or the dispensing beak 23 of the dispense arm 20. The label web advance arm 24 is arcuate and has two rollers at one end thereof, and a third roller at approximately a mid-point thereof. The label web advance arm 24 is arranged to pivot about the other end of label web advance arm 24. The continuous sheet 12 passes between the two rollers at the end of the label web advance arm 24. The dispense arm 20 is arcuate and is arranged to pivot about one end thereof. The dispensing beak 23 is at the other end of the dispense arm 20.

[0076] Figure 3 shows a view the apparatus shown in Figure 2 in a web advance condition. In Figure 3 the label web advance arm 24 is shown to be in a deployed condition where it is pivoted around the label web drive roller 22 so that the arc of the label web advance arm 24 is around the label web drive roller 22. In this position the continuous sheet 12 passed around the third roller of the label web advance arm 24. In Figure 3 the continuous sheet 12 is still not in contact with the dispensing beak 23 of the dispense arm 20.

[0077] Figure 4 shows a view of the apparatus shown in Figure 2 in a dispense arm 20 advance condition. In Figure 4 the dispense arm 20 is shown to be in a deployed condition where it is pivoted into position so that the dispensing beak 23 is pushed into the continuous sheet 12. It will be appreciated that such pushing of the dispensing beak 23 into the continuous sheet 12 requires the dispensing beak to contact or cooperate with the continuous sheet 12. In this position the continuous sheet 12 passed around the dispensing beak 23 to dispense the label web 15 from the continuous sheet 12 and towards the two label web feed rollers 26.

[0078] Figure 5 shows a view of the apparatus shown in Figure 2 in a dispense arm retraction condition. In Figure 5 the dispense arm 20 is shown to be pivoted back to the open condition so that the dispensing beak 23 is out of contact with the continuous sheet 12. In this position the label web 15 continues to be dispensed from the continuous sheet 12 as it is pulled through the two label web feed rollers 26. It will be appreciated that the substrate web 13 still passes through the rest of the apparatus as shown in Figure 5.

[0079] Figure 6 shows a view of the apparatus shown in Figure 2 with a label web advance arm in a retracted condition. In Figure 6 the label web advance arm 24 is shown to be pivoted back to the open condition so that the label web 15 is in contact with the label web drive roller 22. The label web 15 is also in contact with a larger arc of one of the rollers at the end of the label web advance arm 24. In this position the dispense arm 20 remains out of contact with the continuous sheet 12. In Figure 6 the label web 15 is continuously dispensed from the continuous sheet 12, and the label web drive roller 22 and the two label web feed rollers 26 operate together to guide and pull the label web 15 from the continuous sheet 12.

[0080] Figure 7 shows a side view of an air feed device 34 of the apparatus of Figures 1 to 6 according to an embodiment of the invention. In Figure 7, the air feed device 34 is between the two label web feed rollers 26 and the granulator 28. The air feed device 34 is supplied with compressed air to create a thin wall of high velocity air on either side of the label web 15, as shown by two arrows 36. The two walls of high velocity air 36 draws in some of the surrounding air creating a vacuum effect to guide the label web 15 downwards as viewed in the drawing from the two label web feed rollers 26 and into the granulator 28. The two walls of high velocity air 36 also help to keep cut pieces of the label web 15 in the granulator 28, and also counteract effects from the granulator 28 which creates an air flow out of the granulator 28. Figure 8 shows steps of a method according to an embodiment of the invention, generally designated 40. It will be appreciated that the steps may be performed in a different order, and may not necessarily be performed in the order shown in Figure 8.

[0081] The method 40 relates to removing a label web 15 from a continuous sheet 12 using an apparatus 10 comprising a cross-cut device 18, a dispensing blade 23 that is moveable between a deployed position and a retracted position, and label web removal device 26, the continuous sheet 12 comprising a substrate web 13 and the label web 15. The method includes receiving 42 the continuous sheet 12 into the apparatus 10. The method includes cutting 44 the label web 15 across a width thereof using the cross-cut device 18. The method includes moving 48 the dispensing blade 23 to the deployed position to cooperate with the continuous sheet 12 prior to the cross-cut reaching the dispensing blade 23 to dispense the label web 15 from the substrate web 13. The method includes receiving 50 the label web 15 at the label web removal device 26 to draw the label web 15 from the substrate web 13.

[0082] The label web removal device 26 comprises a pair of label web feed rollers 26 to receive the label web 15 therebetween, the method including drawing the label web from the substrate web using the pair of label web feed rollers.

[0083] As discussed below, at least one of the label web feed rollers 26 is a drive roller, the method including drawing the label web 15 from the substrate web 13 using the drive roller. As discussed below, one of the rollers 26 is fixed, and the other roller 26 is movable, and wherein the movable roller is the drive roller, the method including receiving the label web 15 on the movable roller so that a sticky surface of the label web 15 contacts the movable roller and is wound thereon to draw it from the substrate web 13. The movable roller is provided with a sleeve, the method including the sticky surface of the label web contacting the sleeve so that it is wound thereon, and removing the sleeve from the movable roller for disposal of the label web 15.

[0084] As discussed below, the movable roller may be translatable, the method including translational movement of the movable roller as the label web 15 is wound thereon.

[0085] As discussed below, the method further including providing a duct 92 with an inlet, the method including providing the duct 92 with a flow of air 94 via a partial vacuum, and receiving the label web 15 at the inlet to draw it from the substrate web 13.

[0086] As discussed below, a gap is provided between the pair of label web feed rollers 26, the method including setting the gap prior to receiving the label web 15. One of the label web feed rollers 26 is at an inlet opening of the duct 92, the method including drawing a curtain of air around said label web feed roller 26.

[0087] The method further includes moving 52 the dispensing blade 23 back to the retracted position so that the label web 15 continues to be dispensed from the substrate web 13. The apparatus further comprises a label web advance device 24 moveable between a deployed position and a retracted position, the method including moving the label web advance device 24 to the deployed position to advance the continuous sheet prior to the dispensing blade 23 being moveable to the deployed position.

[0088] The apparatus 10 further comprises a label web drive roller 22, the method including moving 54 the label web advance device 24 to the retracted position to at least partially wrap the label web 15 around the label web drive roller 22.

[0089] The method further includes using the cross-cut device 18 to cut the label web at an angle of between 80 to 89 degrees to the direction of travel of the continuous sheet 12. The method further includes using the cross-cut device 18 to cut the label web 15 at an angle of between 85 to 89 degrees to the direction of travel of the continuous sheet 12. The method further includes using the cross-cut device 18 to cut the label web at an angle of substantially 87.5 degrees to the direction of travel of the continuous sheet 12.

[0090] As discussed below, the dispensing blade 23 is mounted on a dispensing arm 20 that is pivotable about one end thereof, the dispensing arm 20 having a contact roller 27, the method further includes contacting the substrate web 13 of the continuous sheet 12 with the contact roller 27 prior to the dispensing blade 23 moving to the deployed position. The method including locating the continuous sheet 12 between the contact roller 27 and one of the label web feed rollers 26 prior to the dispensing blade 23 moving to the deployed position. The method further includes using a granulator 28 to receive the label web 15 from the label web removal device 26, and cutting 56 the label web 15 into granules using the granulator 28.

[0091] The method further includes using 58 an air feed device 34 between the label web removal device 26 and the granulator 28 to direct at least one jet of air 36 onto the label web 15 to guide it into the granulator 28.

[0092] The method further includes using 60 a compactor to receive and compress the granules from the granulator 28.

[0093] It will be appreciated that Figures 2 to 6 shows five side views of an automated label web 15 removal apparatus 10, according to an embodiment of the invention. The five side views shown one method of operation that uses both the dispensing arm 20 (i.e. to dispense the label web 15) and the web advance arm 24 (to wrap the label web 15 onto the label web drive roller 22). This embodiment of the invention has the advantage of using the label web drive roller 22 to control the tension of the label web 15 as it is being removed from the substrate web 13.

[0094] According to another embodiment of the invention only the dispense arm 20 is used to dispense the label web 15 from the continuous sheet 12. In this embodiment the label web advance arm 24 remains in a deployed position as shown in Figure 5, and the step shown in Figure 6 to retract the label web advance arm 24 would not be performed. With such an arrangement there may be less control over the tension of the label web 15 but the process of removing the label web 15 from the substrate web 13 has one less step.

[0095] It will be understood that in the embodiment shown in Figures 2 to 6 the label web drive roller 22 is engaged, whereas the label web drive roller 22 is not used in the embodiment shown in Figures 2 to 5. Both embodiments can be used for removing the label web 15 (i.e. the waste label web) from the substrate web 13. When the label web 15 is required to be removed the operator of the apparatus would initiate the process of moving the dispensing arm 20 and / or the label web advance arm 24 via a control panel of the apparatus 10.

[0096] According to another embodiment of the invention the label web advance arm 24 is not used or present in the apparatus 10, and only the dispense arm 20 is used to dispense the label web 15 from the continuous sheet 12. Such an arrangement may or may not us the label web drive roller 22 to drive the label web 15.

[0097] The first step of the process is for the apparatus 10 to reduce the speed of the continuous sheet 12 to a relatively slow speed (i.e. approximately 5m / min). At this slow speed the cross-cut rollers 18 engage the continuous sheet 12 to create a cross-cut in the face material only (i.e. the label web 15). The cross-cut is made at an angle to the direction of travel of the continuous sheet 12 to reduce the pressure required for the cross-cut. At this stage the continuous sheet 12 could be a complete material (i.e. not die cut), or it could be die cut (i.e. with labels). The position of the cross-cut on the continuous sheet 12 is tracked by the apparatus 10 using a tracking device (e.g. using the rollers within the apparatus which are gear driven and from which the location of the cross-cut on the continuous sheet 12 can be determined, or using at least one sensor of the apparatus and timing marks on the continuous sheet 12), and the dispense arm 20 is automatically actuated by the apparatus 10 at the appropriate time to push the dispensing beak 23 towards the continuous sheet 12 so that it makes contact therewith on the substrate web 13 side of the continuous sheet 12. For example, the apparatus 10 may have a control device coupled to the at least one sensor device for determining the position of the cross-cut and for controlling the actuation of the dispense arm 20. The dispensing beak 12 has an edge over which the continuous sheet 12 runs that causes the face material (i.e. the label web 15) to dispense at the cross cut on the continuous sheet 12.

[0098] The dispensed material, which may be an intact label web 15 or the waste label web known as the matrix, is then feed between the label web feed rollers 26, which are a pair of non-stick rollers that are positioned directly above the granulator 28 (see Figures 1), and feed the dispensed material into the granulator 28. The label web feed rollers 26 have a clutch to control the torque to the rollers, and to provide control of the tension of the dispensed material. At least one of the two label web feed rollers 26 is a drive roller.

[0099] At the next step the dispense arm 20 is retracted, which leaves the dispensed material (i.e. the intact label web 12 or matrix) between the label web feed rollers 26 so that it is continuously stripped away from the substrate web 13 (i.e. the carrier material) as the continuous sheet 12 moves through the apparatus 10. When using the method that includes using the label web drive roller 22 (see Figure 6) the label web advance arm 24 is then retracted, which causes the dispensed material to wrap onto the label web drive roller 22.

[0100] The granulator 28 chops up the dispensed material, which then drops into the compactor 30 where it is compressed and fed to a rear of the apparatus for disposal. The compactor 30 may be positioned on an incline to allow the compacted waste to drop directly into a waste bin.

[0101] It will be appreciated that the invention relates to stripping of the matrix or the complete label web from the continuous sheet 12, and the subsequent management of the waste material by granulation and compaction. Some advantages are that the matrix (or the complete label web) is removed from the continuous sheet 12 in an automated manner, and using a continuous process. Such a continuous process is consistent and highly predictable, and does not require the apparatus 10 to be stopped, which is beneficial for the overall high-speed operation of the apparatus 10, which may be operated 24 hours a day and 7 days a week. Alternatively, for a short production run the embodiments herein provide a way of quickly and automatically changing over from one job to another job. Furthermore, the waste produced by the apparatus 10 is compact and has less volume than an equivalent roll of waste matrix material that may only comprise 10% waste material and 90% air.

[0102] It will be understood that the apparatus and methods described herein may be used to remove a web layer from a substrate web 13. It is envisaged that the web layer is label web for use with create self-adhesive labels from the continuous sheet 12 of material. It will be appreciated that the label web 15 may be cut, printed and / or embossed, and that the apparatus 10 may be part of a larger apparatus for performing such processes on the continuous sheet 12. Typically, the apparatus 10 would be provided before subsequent processes of the continuous sheet 12 (i.e. further cutting, printing or embossing) that may be performed but other modules of the larger apparatus.

[0103] Figure 9 shows a side view of a label web removal apparatus according to another embodiment of the invention, generally designated 70. In Figure 9 like features to the arrangements of Figures 1 to 8 are shown with like reference numerals. In Figure 9 the label web removal apparatus 70 may alternatively be termed a matrix removal apparatus. In Figure 9 the continuous sheet of material 12 is shown with a dashed line as it passes through the apparatus 70, and the direction of travel through the apparatus is shown with an arrow on the dashed line. The continuous sheet 12 comprising the substrate web 13 and the label web 15 (also see Figures 10 to 12).

[0104] As shown in Figure 9, the apparatus 70 has an infeed drive roller 14 to feed the continuous sheet 12 into the apparatus 70. The continuous sheet 12 may then pass on to an edge trim device 16 (not shown) to trim the substrate web 13 to the correct width so that it readily passes through the apparatus 70. The continuous sheet 12 then passes through two cross-cut rollers 18 where one of the rollers has a cutting plate with a blade. The blade may be at 90 degrees to the direction of travel of the continuous sheet 12. The blade may also be at an angle slightly away from 90 degrees to the direction of travel of the continuous sheet 12, for example 80 to 89 degrees, or 85 to 89 degrees, or more preferably substantially 87.5 degrees. The cross-cut rollers 18 create a cut through a full width of the label web 15 only, which may be about 0.1mm thick. Providing the blade at a slight angle reduces the force required to produce the cross-cut in the label web 15 so that the cross-cut on the width of the label web 15 is over about 10mm in length in the direction of travel of the continuous sheet 12. The cutting plate may have up to six or more blades for different thicknesses of the label web 15. Each of the six or more blades being on the cutting plate and having a different height on the surface of the cutting plate.

[0105] The continuous sheet 12 then passes on to the dispense arm 20, the label web drive roller 22, and the label web advance arm 24. The label web advance arm 24 has a roller 25 around which the continue sheet 12 runs, which is controlled to compensate for the change in web length throughout the process. The roller 25 may be termed a dancer roller. The dispense arm 20 has the dispensing beak 23, which is operable to impinge on a full width of the continuous sheet 12 to dispense label web 15 as discussed below with reference to Figures 10 to 12. In Figure 9, the dispensing beak 23 may alternatively be termed a dispensing blade, and may be made of suitably wear-resistant material that also dissipates heat from friction such as steel having a high carbon content (i.e. high tensile steel), or carbon fibre reinforced plastic. An edge of the dispensing beak 23 has a radius of about 1mm, which reduces the chances of cutting the substrate web 13. The radius of the edge maybe in the range 0.5mm to 3mm. It will be appreciated that in Figure 9 the dispensing arm 20 and the label web advance arm 24 are shown in an open position (i.e. a retracted condition). The label web advance arm 24 may be alternatively termed the label web advance device. The label web drive roller 22 drives and controls the tension of the continuous sheet 12. In one arrangement the label web drive roller 22 may have a textured surface (i.e. a knurled surface or a patterned surface) to provide additional grip to the continuous sheet 12.

[0106] Also shown in Figure 9 are the two label web feed rollers 26, which are the pair of rollers mentioned above in relation to the embodiment of Figures 1 to 8. In Figure 9, one of the rollers 26 is rotatable and fixed, and the other roller 26 is rotatable and movable so that it is translatable in a direction shown by arrow 72 to a position show at 74. The fixed roller 26 is driven by the continuous sheet 12, but may also be a driven roller. The fixed roller 26 may have a rubber surface to provide additional grip to the label web 15. The movable roller 26 receives the label web 15 and is wound on to the movable roller 26 up to a maximum size of the movable roller 26 shown at 76. When the movable roller 26 is at a maximum size it can be removed from the apparatus 70 so that the label web 15 can be disposed of.

[0107] It will be appreciated that the movable roller 26 may be fitted with a sleeve (e.g. a cardboard sleeve) prior to receiving the label web 15 for ready removal thereof from the movable roller 26 when full. A typical maximum diameter of the label web 15 on the cardboard sleeve may be up to 80cm. The movable roller 26 may also be movable between a contact position to an extraction position. In the contact position a surface of movable roller 26 (i.e. the sleeve or the waste label web 15) is in contact with the fixed roller 26 to draw the label web 15 from the continuous sheet 12. In the extraction position the surface of movable roller 26 (i.e. the sleeve or the waste label web 15) is not in contact with the fixed roller 26 so that the sleeve can be removed from the apparatus 70. Such an extraction position may be provided by a cam-stop (not shown) of the movable roller 26 whereby the movable roller 26 is adjustable in position (i.e. by about 0.5cm to 2cm) as well as being translatable as shown by arrow 72.

[0108] The label web feed rollers 26 may be alternatively termed label web rollers 26, and are in contact with one another (i.e. the sleeve or the waste label web 15) prior to dispensing of the label web 15 to grip and feed the label web 15 onto the movable roller 26 (i.e. the cardboard sleeve). The label web feed rollers 26 may be alternatively termed a label web removal device.

[0109] Figure 10 shows a view of a part of the apparatus 70 shown in Figure 9 in a starting condition. In Figure 10 the dispensing arm 20, the label web advance arm 24, and the dispensing beak 23 are shown in a retracted position, and the two label web feed rollers 26 are shown in contact with one another. The dispensing arm 20 is also shown to have a contact roller 27 for contact with the substrate web 13 of the continuous sheet 12 as discussed with reference to Figures 11 and 12. In Figure 10 the contact roller 27 is not in contact with the substrate web 13 of the continuous sheet 12.

[0110] Figure 11 shows a view the apparatus 70 shown in Figure 10 in a partial web advance condition. In Figure 11 the dispensing arm 20 is shown to be pivoted about an axis 29 into a deployed position so that the contact roller 27 is in contact with the substrate web 13, and so that the continuous sheet 12 is between the contact roller 27 and the fixed roller 26. The label web advance arm 24 is also shown to be pivoted about an axis 21 so that it is in a partially deployed position. With the dispensing arm 20 in the deployed position the beak 23 remains in a stowed position so that it is not in contact with the substrate web 13 of the continuous sheet 12. The dispensing arm 20 may be alternatively termed a pivotable dispensing member.

[0111] It will be appreciated that when the dispensing arm 20 moves to the deployed position with the contact roller 27 in contact with the substrate web 13, there is a change in web length. The apparatus 70 is operated to control a position of label web advance arm 24 as shown in Figure 11 to compensate for this change in web length.

[0112] Figure 12 shows a view of the apparatus 70 shown in Figure 10 in a label web dispense condition. In Figure 12 the label web advance arm 24 is shown to be further pivoted about the axis 21 so that it is in a fully deployed position. The dispensing beak 23 is also shown to be in the deployed position so that it is in contact with and pushed into the continuous sheet 12. The operation of the dispensing beak 23 between the deployed and the stowed positions may be pneumatically controlled (i.e via a pneumatic actuator arrangement). Such pushing of the dispensing beak 23 into the continuous sheet 12 requires the dispensing beak 23 to contact or cooperate with the continuous sheet 12 (i.e. the substrate web 13). The continuous sheet 12 passed around the dispensing beak 23 to dispense the label web 15 from the continuous sheet 12 so that it is pushed between the two label web feed rollers 26.

[0113] The dispensing beak 23 is operable between the stowed and the deployed positions at a tangent to the contact roller 27. As such, one side of the dispensing beak 23 passes close to the contact roller 27 during operable between the stowed and the deployed positions. For example, a gap between the one side of the dispensing beak 23 and the contact roller 27 may be between 1mm to 5mm.

[0114] It will be appreciated that when the dispensing beak 23 moves to the deployed position in contact with the substrate web 13, there is a change in web length. The apparatus 70 is operated to control a position of label web advance arm 24 to the fully deployed position as shown in Figure 12 to compensate for this change in web length.

[0115] Due to the configuration of the two label web feed rollers 26, the sticky surface of the label web 15 contacts the movable roller 26 (i.e. the cardboard sleeve) so that the label web 15 sticks to the cardboard sleeve and is wound around the movable roller 26. As the movable roller 26 receives the label web 15 the diameter thereof gets larger, and it moves in a translatable manner as shown by arrow 72 to position 74 where it is at a maximum size. The movement of the dispensing beak 23 to the deployed position is timed to cooperate with the continuous sheet 12 prior to the cross-cut reaching the dispensing beak 23. After the label web 15 has started to wind around the movable roller 26 the dispensing beak 23, the label web advance arm 24, and the dispensing arm 20 then move back to their starting positions as shown in Figure 10.

[0116] From the foregoing the skilled person will understand that the sequences described above with reference to Figures 10, 11 and 12 are performed in order. It will be appreciated that the steps may be performed in a different order, and may not necessarily be performed in the order shown in Figure 10, 11 and 12. Figure 13 shows a side view of a label web removal apparatus according to another embodiment of the invention, generally designated 90. In Figure 13 like features to the arrangements of Figures 9 to 12 are shown with like reference numerals. In Figure 13 the label web removal apparatus 90 may alternatively be termed a matrix removal apparatus. In Figure 13 the continuous sheet of material 12 is shown with a dashed line as it passes through the apparatus 90, and the direction of travel through the apparatus is shown with an arrow on the dashed line. The continuous sheet 12 comprising the substrate web 13 and the label web 15 (also see Figures 14 to 16).

[0117] As shown in Figure 13, the apparatus 90 has an infeed drive roller 14 to feed the continuous sheet 12 into the apparatus 90. The continuous sheet 12 may then pass on to an edge trim device 16 (not shown) to trim the substrate web 13 to the correct width so that it readily passes through the apparatus 90. The continuous sheet 12 then passes through two cross-cut rollers 18 where one of the rollers has a cutting plate with a blade. The blade arrangements may be similar to the embodiments shown in Figure 1 to 12. The cross-cut rollers 18 create a cut through a full width of the label web 15 only. Providing the blade at a slight angle reduces the force required to produce the cross-cut in the label web 15 so that the cross-cut on the width of the label web 15 is over about 10mm in length in the direction of travel of the continuous sheet 12. The cutting plate may have up to six or more blades for different thicknesses of the label web 15. Each of the six or more blades being on the cutting plate and having a different height on the surface of the cutting plate. The continuous sheet 12 then passes on to the dispense arm 20, the label web drive roller 22, and the label web advance arm 24. The label web advance arm 24 has a roller

[0118] 25 around which the continue sheet 12 runs, which is controlled to compensate for the change in web length throughout the process. The roller 25 may be termed a dancer roller. The dispense arm 20 has the dispensing beak 23, which is operable to impinge on a full width of the continuous sheet 12 to dispense label web 15 as discussed below with reference to Figures 14 to 16. In Figure 13, the dispensing beak 23 may alternatively be termed a dispensing blade, and may be made of suitably wear-resistant material that also dissipates heat from friction such as steel having a high carbon content (i.e. high tensile steel), or carbon fibre reinforced plastic. An edge of the dispensing beak 23 has a radius of about 1mm, which reduces the chances of cutting the substrate web 13. The radius of the edge maybe in the range 0.5mm to 3mm. It will be appreciated that in Figure 13 the dispensing arm 20 and the label web advance arm 24 are shown in an open position (i.e. a retracted condition). The label web advance arm 24 may be alternatively termed the label web advance device. The label web drive roller 22 drives and controls the tension of the continuous sheet 12. In one arrangement the label web drive roller 22 may have a textured surface (i.e. a knurled surface or a patterned surface) to provide additional grip to the continuous sheet 12.

[0119] Also shown in Figure 13 are the two label web feed rollers 26, which are the pair of rollers mentioned above in relation to the embodiments of Figures 1 to 12. In Figure 13, the two rollers 26 are rotatable and fixed. One of rollers 26 is driven by the continuous sheet 12, but may also be a driven roller. The roller 26 may have a rubber surface to provide additional grip to the label web 15. Also shown is a duct 92, which is provided with a flow of air 94 via a partial vacuum. The duct 92 provides a way of pulling the label web 15 away from the continuous sheet 12 and to receive the label web 15 for disposal.

[0120] One of the rollers 26 is at an inlet opening of the duct 92 so that a curtain of air is drawn around the roller 26, which promotes removal of the label web 15 as mentioned below. The inlet opening of the duct 92 may be substantially the same shape as the roller 26 whilst retaining an air gap around the rolling surface of the roller 26 and to direct air flow around the roller 26. The duct 92 may be close fitting with an end of the roller 26 to minimise air loss at ends thereof. The roller 26 within the opening of the duct 92 may be fitted with a sleeve (e.g. an aluminium sleeve) which may have a non-stick coating (i.e. substantially non-stick) to reduce the possibility for the label web 15 to stick to it. A gap is provided between the two rollers 26 to reduce the possibility for the label web 15 sticking to the roller 26 within the opening of the duct 92. The gap is about 10mm, but may also be in the range 5mm to 20mm. Typically a gap of 8mm to 9mm has been found to be suitable. The skilled person will understand that a smaller gap may increase the speed of the flow of air into the duct 92, whereas as larger gap may reduce the speed of the flow of air into the duct 92. However, a balance needs to be considered because a smaller gap may also increase the chances of the label web 15 sticking to the roller 26 within the opening of the duct 92. The gap may be adjusted using the cam-stop (not shown and mentioned above in relation to Figures 9 to 12) of the roller 26 within the opening of the duct 92 whereby it is adjustable in position (i.e. by about 5mm to 20mm). The label web feed rollers 26 may be alternatively termed label web rollers 26, and are not in contact with one another during operation of the embodiment shown in Figures 13 to 16. The label web feed rollers 26 may be alternatively termed a label web removal device.

[0121] Figure 14 shows a view of a part of the apparatus 90 shown in Figure 13 in a starting condition. In Figure 14 the dispensing arm 20, the label web advance arm 24, and the dispensing beak 23 are shown in a retracted position, and the two label web feed rollers 26 are not in contact with one another. The dispensing arm 20 is also shown to have a contact roller 27 for contact with the substrate web 13 of the continuous sheet 12 as discussed with reference to Figures 15 and 16. In Figure 14 the contact roller 27 is not in contact with the substrate web 13 of the continuous sheet 12. In the starting condition the flow of air 94 is initiated (e.g. using an extractor fan), which draws air around the roller 26 within the opening of the duct 94 as shown by arrows 96.

[0122] Figure 15 shows a view the apparatus 90 shown in Figure 14 in a partial web advance condition. In Figure 15 the dispensing arm 20 is shown to be pivoted about an axis 29 into a deployed position so that the contact roller 27 is in contact with the substrate web 13, and so that the continuous sheet 12 is between the contact roller 27 and one of the rollers 26. The label web advance arm 24 is also shown to be pivoted about an axis 21 so that it is in a partially deployed position. With the dispensing arm 20 in the deployed position the beak 23 remains in a stowed position so that it is not in contact with the substrate web 13 of the continuous sheet 12. The dispensing arm 20 may be alternatively termed a pivotable dispensing member. In Figure 15 the arrows 96 have been omitted for clarity, but it will be understood that air is still dawn around the roller 26 within the opening of the duct 94 during operation of the apparatus 90 shown in Figure 15.

[0123] It will be appreciated that when the dispensing arm 20 moves to the deployed position with the contact roller 27 in contact with the substrate web 13, there is a change in web length. The apparatus 90 is operated to control a position of label web advance arm 24 as shown in Figure 15 to compensate for this change in web length.

[0124] Figure 16 shows a view of the apparatus 90 shown in Figure 14 in a label web dispense condition. In Figure 16 the label web advance arm 24 is shown to be further pivoted about the axis 21 so that it is in a fully deployed position. The dispensing beak 23 is also shown to be in the deployed position so that it is in contact with and pushed into the continuous sheet 12. The operation of the dispensing beak 23 between the deployed and the stowed positions may be pneumatically controlled (i.e via a pneumatic actuator arrangement). It will be appreciated that such pushing of the dispensing beak 23 into the continuous sheet 12 requires the dispensing beak 23 to contact or cooperate with the continuous sheet 12 (i.e. the substrate web 13). The continuous sheet 12 passed around the dispensing beak 23 to dispense the label web 15 from the continuous sheet 12 so that it is pushed into the gap between the two label web feed rollers 26. In Figure 16 the arrows 96 have been omitted for clarity, but it will be understood that air is still dawn around the roller 26 within the opening of the duct 94 during operation of the apparatus 90 shown in Figure 16. It will be appreciated that when the dispensing beak 23 moves to the deployed position in contact with the substrate web 13, there is a change in web length. The apparatus 90 is operated to control a position of label web advance arm 24 to the fully deployed position as shown in Figure 16 to compensate for this change in web length.

[0125] Due to the configuration of the two label web feed rollers 26 having the gap, the sticky surface of the label web 15 does not stick to the rollers 26 (i.e. the aluminium sleeve) due to the air flow shown by arrows 96. As the duct 92 receives the label web 15 it is drawn along the duct 92 by the current of air as shown by arrow 94. The movement of the dispensing beak 23 to the deployed position is timed to cooperate with the continuous sheet 12 prior to the cross-cut reaching the dispensing beak 23. After the label web 15 has started to be drawn from the substrate web 13 the dispensing beak 23, the label web advance arm 24, and the dispensing arm 20 then move back to their starting positions as shown in Figure 14.

[0126] From the foregoing the skilled person will understand that the sequences described above with reference to Figures 14, 15 and 16 are performed in order. It will be appreciated that the steps may be performed in a different order, and may not necessarily be performed in the order shown in Figure 14, 15 and 16.

[0127] The gap between the rollers 26, and between the duct 92 and the rollers, is an important aspect of the embodiment shown in Figure 13, 14, 15 and 16. The gap reduces or avoids sticking of the label web 15 to the rollers and / or the duct 92. The duct 92 may also be provided with a non-stick inner surface (i.e. substantially non-stick), and in particular the non-stick inner surface is provided around the roller 26 within an opening of the duct 92. In one arrangement a portion of an inner surface of the duct 92 which is underneath the roller 26 within the opening is provided with the non-stick inner surface. The roller 26 (i.e. and the sleeve) within the opening of the duct 92 may also be driven during operation of the apparatus 90, which may further assist with reducing the possibility for the label web 15 to become stuck thereto. Whereas Figures 13 to 16 show side views it will be appreciated that at the sides the duct 92 may be close fitting at the end of the roller 26 within the opening of the duct 92 to reduce air loss at the end of the roller 26.

[0128] The embodiments shown in Figures 9 to 12 and Figures 13 to 16 are similar and may use parts of the same underlying apparatus. For example, the movable roller 26 of Figures 9 to 12 may be retained in a fixed position for use the embodiment shown in Figures 13 to 16.

[0129] An advantage of the apparatus discuss herein is that the waste label web 15 (i.e. the matrix) can be readily dispensed from the substrate web 13 in an automated manner, and subsequently disposed of. Typically, the full label web 15 may be removed by known devices, but the matrix is very hard to remove. However, the above embodiments and apparatus provide a reliable way to automate the process of removing the label web 15 irrespective of whether it is a full label web 15 or a waste label web (matrix), and which does not require the apparatus to be stopped. Furthermore, the prior known ways of removing the full label web 15 (or matrix) require a certain amount of manual intervention to pick the label web 15 (or matrix) off the substrate web 13 at the start of the stripping process. However, the above embodiments and apparatus avoid the need for such manual intervention, and automate the process to provide an automatic matrix dispensing apparatus.

[0130] An advantage of the arrangement of Figure 9 to 16 is that the label web drive roller 22 drives and controls the tension of the continuous sheet 12, and at the same time the two label web feed rollers 26 drive and control the tension of the label web 15. Such an advantage is provided by arrangement of the fixed roller 26, the movable roller 26, the drive roller 22 and / or the flow of air. In the arrangement shown in Figures 13 to 16 the partial vacuum controls the tension of the label web 15.

[0131] With the above embodiments the multiple cutting blades for different thicknesses of the label web 15 are advantageous over a single blade having one cutting height because it saves setup time.

[0132] It is envisaged that the apparatus 10 may be further automated using pre-programmed parameters for a particular task. For example, standard formats or parameters may be stored in a library and used as required to automate job setup for the apparatus 10. The library may contain various parameters relating to material thickness, set-up specifications for the cross-cut of the material, and cross-references to a library of materials to further assist with automation and smooth operation of the apparatus 10.

Claims

CLAIMS1. An apparatus for removing a label web from a continuous sheet comprising a substrate web and the label web, the apparatus comprising a cross-cut device to impart a cross-cut on a full width of the label web, a dispensing blade being movable between a deployed position and a retracted position, and a label web removal device, the apparatus being adapted to receive the continuous sheet into the apparatus, the dispensing blade being operable to the deployed position to cooperate with the continuous sheet prior to the cross-cut reaching the dispensing blade during operation of the apparatus to dispense the label web from the substrate web, wherein the label web removal device is operable to receive the label web and to draw the label web from the substrate web.

2. An apparatus according to claim 1, wherein the label web removal device comprises a pair of label web feed rollers to receive the label web therebetween.

3. An apparatus according to claim 2, wherein at least one of the label web feed rollers is a drive roller.

4. An apparatus according to claim 2 or 3, wherein one of the rollers is fixed, and the other roller is movable.

5. An apparatus according to claim 4, wherein the movable roller is the drive roller that is operable to receive the label web such that a sticky surface of the label web isoperable to contact the movable roller and is wound thereon to draw it from the substrate web.

6. An apparatus according to claim 5, wherein the movable roller is provided with a sleeve, the sticky surface of the label web arranged to contact the sleeve and be wound thereon, the sleeve being removable from the movable roller for disposal of the label web.

7. An apparatus according to claim 5 or 6, wherein the movable roller is translatable as the label web is wound thereon.

8. An apparatus according to claim 6 or 7, wherein the pair of label web feed rollers, or the sleeve and one of the label web feed rollers, are in contact with one another prior to receiving the label web.

9. An apparatus according to any of claims 2 to 4, and further including a duct being provided with a flow of air via a partial vacuum, the duct having an inlet being operable to receive the label web and to draw it from the substrate web.

10. An apparatus according to claim 9, wherein a gap is provided between the pair of label web feed rollers prior to receiving the label web.

11. An apparatus according to claim 10, wherein the gap is between 5mm and 20mm, and preferably 10mm.

12. An apparatus according to any of claims 9 to 11, wherein one of the label web feed rollers is at an inlet opening of the duct such that a curtain of air is drawn around said label web feed roller.

13. An apparatus according to claim 12, wherein the duct is close fitting with an end of said label web feed roller.

14. An apparatus according to claim 12 or 13, wherein said label web feed roller is provided with a non-stick surface.

15. An apparatus according to claim 14, wherein said label web feed roller is provided with a sleeve having the non-stick surface.

16. An apparatus according to any of claims 12 to 15, when dependent on claim 3, wherein said label web feed roller is the drive roller.

17. An apparatus according to any of claims 9 to 16, wherein an inner surface of the duct has a non-stick inner surface.

18. An apparatus according to claim 17, wherein the non-stick inner surface is provided on at least a portion of the inlet of the duct.

19. An apparatus according to any preceding claim, wherein the dispensing blade is movable back to the retracted position and the label web continues to be dispensed from the substrate web during operation of the apparatus.

20. An apparatus according to any preceding claim, further comprising a label web advance device being moveable between a deployed position and a retracted position, wherein the label web advance device is operable to the deployed position to advance the continuous sheet prior to the dispensing blade being moveable to the deployed position.

21. An apparatus according to claim 20, further comprising a label web drive roller, wherein the label web advance device is operable to the retracted position to at least partially wrap the label web around the label web drive roller.

22. An apparatus according to claim 20 or 21, wherein the label web advance device is a label web advance arm that is pivotable about one end thereof.

23. An apparatus according to any of claims 20 to 22, wherein the label web advance device has one or more rollers thereon.

24. An apparatus according to any preceding claim, wherein the cross-cut device comprises a pair of cross-cut rollers, one of the cross-cut rollers having at least one cutting blade.

25. An apparatus according to claim 24, wherein the blade is at an angle of between 80 to 89 degrees to the direction of travel of the continuous sheet.

26. An apparatus according to claim 25, wherein the angle is between 85 to 89 degrees to the direction of travel of the continuous sheet.

27. An apparatus according to claim 26, wherein the angle is substantially 87.5 degrees to the direction of travel of the continuous sheet.

28. An apparatus according to any of claim 24 to 27, wherein the cutting blade comprises one of up to six or more cutting blades that are mounted on a cutting plate of one of the cross-cut rollers, each cutting blade being of a different height on the surface of the cutting plate.

29. An apparatus according to any preceding claim, wherein the dispensing blade is mounted on a dispensing arm that is pivotable about one end thereof.

30. An apparatus according to claim 29, wherein the dispensing arm has a contact roller for contact with the substrate web of the continuous sheet prior to the dispensing blade moving to the deployed position to cooperate with the continuous sheet.

31. An apparatus according to claim 30, when depending on any of claims 2 to 18, wherein the continuous sheet is between the contact roller and one of the label web feed rollers prior to the dispensing blade moving to the deployed position.

32. An apparatus according to any preceding claim, and further comprising a granulator to receive the label web from the label web removal device and to cut the label web into granules.

33. An apparatus according to claim 32, comprising an air feed device between the label web removal device and the granulator, and being operable to direct at least one jet of air onto the label web to guide it into the granulator.

34. An apparatus according to claim 33, wherein the air feed device is operable to direct a first jet of air on one side of the label web, and a second jet of air on the other side of the label web.

35. An apparatus according to claim 33 or 34, wherein each jet of air comprises a curtain of air that is substantially across a full width of the label web.

36. An apparatus according to any of claims 32 to 35, and further including a compactor to receive and compress the granules from the granulator.

37. An apparatus according to any preceding claim, comprising at least one tracking device for monitoring the continuous sheet within the apparatus and to determine the position of the cross-cut.

38. An apparatus according to 37, wherein the continuous sheet has a plurality of markers thereon, and the tracking device comprises at least one sensor device being operable to detect the markers to determine the position of the cross-cut.

39. An apparatus according to 37 or 38, wherein the tracking device comprises at least one roller of the apparatus to determine the position of the cross-cut.

40. A method of operating an apparatus according to any preceding claim for removing a label web from a continuous sheet comprising a substrate web and the label web.

41. A method of removing a label web from a continuous sheet using an apparatus comprising a cross-cut device, a dispensing blade that is moveable between a deployed position and a retracted position, and a label web removal device, the continuous sheet comprising a substrate web and the label web, the method including: receiving the continuous sheet into the apparatus; cutting the label web across a width thereof using the cross-cut device; moving the dispensing blade to the deployed position to cooperate with the continuous sheet prior to the cross-cut reaching the dispensing blade to dispense the label web from the substrate web; and receiving the label web at the label web removal device to draw the label web from the substrate web.

42. A method according to claim 41, wherein the label web removal device comprises a pair of label web feed rollers to receive the label web therebetween, the method including drawing the label web from the substrate web using the pair of label web feed rollers.

43. A method according to claim 42, wherein at least one of the label web feed rollers is a drive roller, the method including drawing the label web from the substrate web using the drive roller.

44. A method according to claim 42 or 43, wherein one of the rollers is fixed, and the other roller is movable, and wherein the movable roller is the drive roller, the method including receiving the label web on the movable roller so that a sticky surface of the label web contacts the movable roller and is wound thereon to draw it from the substrate web.

45. A method according to claim 44, wherein the movable roller is provided with a sleeve, the method including the sticky surface of the label web contacting the sleeve so that it is wound thereon, and removing the sleeve from the movable roller for disposal of the label web.

46. A method according to claim 44 or 45, wherein the movable roller is translatable, the method including translational movement of the movable roller as the label web is wound thereon.

47. A method according to claim 42 or 43, and further including a duct with an inlet, the method including providing the duct with a flow of air via a partial vacuum, and receiving the label web at the inlet to draw it from the substrate web.

48. A method according to claim 47, wherein a gap is provided between the pair of label web feed rollers, the method including setting the gap prior to receiving the label web.

49. A method according to claim 47 or 48, wherein one of the label web feed rollers is at an inlet opening of the duct, the method including drawing a curtain of air around said label web feed roller.

50. A method according to any of claims 41 to 49, and further including moving the dispensing blade back to the retracted position so that the label web continues to be dispensed from the substrate web.

51. A method according to any of claims 41 to 50, further comprising a label web advance device moveable between a deployed position and a retracted position, the method including moving the label web advance device to the deployed position to advance the continuous sheet prior to the dispensing blade being moveable to the deployed position.

52. A method according to claim 51, the apparatus further comprising a label web drive roller, the method including moving the label web advance device to the retracted position to at least partially wrap the label web around the label web drive roller.

53. A method according to any of claims 41 to 52, and further including using the cross-cut device to cut the label web at an angle of between 80 to 89 degrees to the direction of travel of the continuous sheet.

54. A method according to claim 53, and further including using the cross-cut device to cut the label web at an angle of between 85 to 89 degrees to the direction of travel of the continuous sheet.

55. A method according to claim 54, and further including using the cross-cut device to cut the label web at an angle of substantially 87.5 degrees to the direction of travel of the continuous sheet.

56. A method according to any of claims 41 to 55, wherein the dispensing blade is mounted on a dispensing arm that is pivotable about one end thereof, the dispensing arm having a contact roller, the method further including contacting the substrate web of the continuous sheet with the contact roller prior to the dispensing blade moving to the deployed position.

57. A method according to claim 56, when depending on any of claims 42 to 49, the method including locating the continuous sheet between the contact roller and one of the label web feed rollers prior to the dispensing blade moving to the deployed position.

58. A method according to any of claims 41 to 57, and further including using a granulator to receive the label web from the label web removal device, and cutting the label web into granules using the granulator.

59. A method according to claims 41 to 58, and further including using an air feed device between the label web removal device and the granulator to direct at least one jet of air onto the label web to guide it into the granulator.

60. A method according to claims 41 or 59, and further including using a compactor to receive and compress the granules from the granulator.

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