Offset Printing System for Vials Using UV Curing
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Solution Overview
Problem
Existing methods for labeling vials, such as using paper labels and toxic inks, are inefficient and pose health and environmental risks, especially when labeling pharmaceuticals or irregularly shaped containers.
Innovation Solution
An offset printing system using a conveyor belt with indented rollers and UV dryers to print on both sides of vials filled with pharmaceuticals, ensuring safety and efficiency by curing the ink before it penetrates the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If paper labels and toxic inks are used for labeling vials, then labeling information can be provided, but health and environmental risks increase and production efficiency decreases
Solution Approach 1:
The patent replaces the mechanical process of applying paper labels with an offset printing system that directly prints onto the vial surface. This substitution eliminates the need for separate labeling machinery and toxic adhesives, while maintaining high-speed production capability through continuous printing operation.
Solution Approach 2:
The patent introduces a UV-curable ink as an intermediary substance that bridges the need for durable labeling and safety requirements. The UV ink contains photoinitiators that remain dormant until exposed to UV light, at which point they rapidly crosslink to form an impermeable, non-toxic film that adheres directly to the vial surface without requiring separate adhesives.
2Reliability
If UV curing is applied to the ink, then ink impermeability and safety are improved, but the complexity of the printing system increases
Solution Approach 1:
The patent combines the printing and curing operations into a single integrated offset printing press. The UV curing lamps are built into the printing mechanism itself, allowing ink to be deposited and cured in one continuous pass through the machine, eliminating the need for separate curing equipment and reducing overall system complexity.
Solution Approach 2:
The patent incorporates UV curing lamps positioned immediately after the ink transfer point in the printing sequence. This preliminary curing action ensures the ink is fully crosslinked and impermeable before the vial leaves the printing station, guaranteeing safety and reliability without requiring additional processing steps downstream.
3Productivity
If direct printing onto vials is implemented, then labeling efficiency is improved, but the requirement for specialized printing equipment increases
Solution Approach 1:
The patent designs the offset printing press with universal applicability to various vial shapes and sizes by incorporating adjustable printing plates and flexible ink transfer mechanisms. The same basic printing platform can handle different pharmaceutical containers by simply changing the printing plate configuration, eliminating the need for multiple specialized printing systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables fast, efficient, and safe mass production of labeled vials without paper labels or toxic inks, ensuring the ink is impermeable and safe for medical use, while accommodating various vial sizes and shapes.
Implementation Method 1
a first ultra violet dryer positioned to receive the vials from the first offset inking transfer device and provide for drying of the ink pattern from the first offset inking transfer device
Implementation Method 2
a first offset inking transfer device for printing a first ink pattern onto the vials
Data Source
AI summary
A method of printing onto closed vial units. The vial units are formed in a series and the vial units have a drug therein. The method involves providing the series of vial units onto a conveyor belt; positioning the vial units adjacent cleats on the conveyor belt; engaging a first offset inking transfer device on a fist side of said vial units; engaging a first back-up roller against said vial units, said first back-up roller being placed opposite said first offset inking transfer device; capturing the vial units between said first back-up roller and said first offset inking transfer device; printing onto the vial units with said first offset inking transfer device; and curing the ink with a first ultra violet dryer.