Packaging Mark Registration Using Pre-Printed Reference Geometry
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Solution Overview
Problem
Existing flexography processes struggle to accurately position dynamic prints on packaging materials due to dimensional changes and web movement, leading to misalignment and readability issues, especially in wide webs with multiple lanes.
Innovation Solution
A method involving pre-printing a static element on packaging material, detecting its reference geometry, and using laser ablation to remove sections to create a negative of the dynamic mark, adjusting the position and orientation based on geometric relationships to ensure accurate placement and readability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate printing station with inkjet technology is used to provide dynamic prints, then unique two-dimensional codes can be printed, but positioning accuracy deteriorates due to dimensional changes and web movement
Solution Approach 1:
The system pre-prints static reference elements (bars, squares, circles) at defined positions on the packaging material before the dynamic printing stage. These reference elements serve as predetermined markers that enable subsequent accurate positioning of dynamic prints despite web movement or dimensional changes during processing.
Solution Approach 2:
The system uses optical sensors or cameras to detect the actual positions of the pre-printed reference elements, compares them with expected positions, and generates feedback signals to adjust the positioning of the dynamic printing station. This closed-loop control ensures accurate registration between static and dynamic prints.
2Productivity
If high-speed flexography processes are used for printing décor, then printing speed increases, but positioning precision of subsequent dynamic prints deteriorates
Solution Approach 1:
The flexography process pre-prints static reference elements along with the décor at high speed. These reference elements are integrated into the high-speed printing process itself, allowing subsequent dynamic printing to be accurately positioned relative to the pre-printed elements without compromising the high-speed production capability.
3Productivity
If the packaging material web width is increased to accommodate multiple lanes, then productivity increases, but positioning accuracy of dynamic prints at outer lanes deteriorates
Solution Approach 1:
The system divides the wide packaging material web into multiple lanes, each with its own set of pre-printed reference elements. This segmentation allows independent positioning control for each lane, ensuring that dynamic prints are accurately positioned even at the outer lanes where web movement and dimensional changes have the greatest impact.
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
Ensures high-quality, accurately positioned dynamic marks, such as two-dimensional codes, by compensating for dimensional changes and web movement, allowing for continuous flow manufacturing at high velocities.
Implementation Method 1
at least one laser unit (38) arranged to remove portions of the at least one pre-printed element (18)
Data Source
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AI summary
The present disclosure refers to a method of manufacturing a mark (34) on a packaging material (16), the method comprising the following steps: Providing the packaging material (16), which comprises at least one pre-printed element (18) at a pre-defined position (20); Removing the pre-printed element (18) in pre-defined sections (32) in a marking station (12), so that the removed sections (32) reflect a negative of the mark (34) to be manufactured; Detecting a reference geometry (44) of the pre-printed element (18) and a reference geometry (46) of the manufactured negative of the mark (34); Determining a geometric relationship (56) of the detected reference geometries (44; 46); Evaluating, if the determined geometric relationship (56) matches a pre-defined geometric relationship; and if it matches, manufacturing subsequent marks (34) under removal of the pre-printed element (18) in the same pre-defined sections (32); or if it does not match, manufacturing subsequent marks (34) under adjustment of the pre-definition of the sections (32), wherein the pre-printed element (18) is removed. The present disclosure further refers to a respective marking station (12) and a packaging material manufacturing system (10), as well as, a packaging material (16) and a packaging container.