Label Web Digital Printing with Indicating Element
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Solution Overview
Problem
Existing label manufacturing processes are inefficient and costly when producing multiple label variants, often resulting in undesirable mixing of different variants due to machine downtime and lack of effective separation methods.
Innovation Solution
A method involving digital printing and die-cutting of a source material web to create distinct label variants, utilizing a machine-readable indicating element for automated separation and ensuring high-quality, cost-effective production without machine stops, allowing for continuous production and separation of label variants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional printing methods are used to produce multiple label variants, then production costs increase and machine downtime occurs, but label variants can be produced
Solution Approach 1:
The patent applies preliminary action by pre-forming a common basic print (such as company logo, color bars, and static elements) on the source material web before the digital printing step. This allows the digital printing device to only need to add the variable label variants without requiring complete reprints, thereby enabling continuous operation and eliminating machine downtime when switching between variants.
Solution Approach 2:
The patent uses copying by employing digital printing technology to create label variants. Instead of using physical printing plates or templates that require replacement, the system digitally copies and applies different label designs to the continuous source material web, enabling rapid switching between variants without stopping the production line.
2Productivity
If labels of different variants are produced continuously without separation, then production cost decreases, but undesirable mixing of variants occurs
Solution Approach 1:
The patent applies segmentation by dividing the label production process into distinct segments: a first processing section that forms the common basic print and digital label variants continuously, and a second processing section that receives the source material web and separates it into individual label variant rolls. This segmentation allows continuous production while ensuring pure separation of different label variants into separate rolls.
Solution Approach 2:
The patent uses an intermediary approach by introducing a control device with a camera as a mediator between the digital printing process and the final label separation. The control device detects features on the source material web and provides control signals to the cutting device, enabling precise and automated separation points based on detected label variant characteristics.
3Adaptability or versatility
If digital printing is used for all label variants, then production cost increases, but flexibility and speed improve
Solution Approach 1:
The patent applies preliminary action by pre-forming the common basic print (company logo, color bars, static elements) using conventional printing methods before the digital printing step. This reduces the amount of digital printing required for each label variant, thereby lowering production costs while maintaining the flexibility to quickly change between different label variants through digital printing alone.
Data Source
AI summary
A method for producing labels of different label variants includes: performing first and second printing operations to form on a source material web using a digital printing device first and second digital prints associated with first and second label variants, respectively, the two digital prints differing at least with respect to a respective print image; forming on the source material web a machine-readable indicating element detectably different from the first and second label variants and arranged to indicate a change of label variant type; and die cutting to form a material web and processing the web, including controlling and making up the first label variant, detecting the indicating element using a controller, cutting the web in the transition between the label variants and controlling and making up the second label variant so that separate first and second label webs are formed with the first and second label variants, respectively.