Reel Tag Data Integration for Packaging Alignment
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Solution Overview
Problem
Existing roll-fed packaging systems face challenges in reliably providing data for on-site printing of packaging materials, leading to misalignments and inefficiencies in customizing packages, as well as in linking the printing module and packaging machine effectively.
Innovation Solution
A method and system that capture reel data from a tag attached to the packaging material, transfer it to a printing information database, and then to a packaging machine information database, allowing for accurate printing and packaging of liquid food products by using pre-printed and on-site printed sections with reference objects for alignment, and integrating data for pre-treatment, printing, and packaging machine settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If on-site printing is used to customize packages, then flexibility and customization possibilities are improved, but misalignment between pre-printed and on-site printed sections occurs
Solution Approach 1:
The system performs preliminary actions by capturing reel data from tags attached to packaging material reels before printing occurs. This data is stored in databases and used to pre-coordinate the printing process, ensuring that on-site printing aligns correctly with pre-printed sections. The reel data includes information about package dimensions, patterns, and positioning that enables accurate alignment before the actual printing takes place.
Solution Approach 2:
The system implements feedback mechanisms by continuously monitoring and comparing actual printing positions with target positions derived from reel data. The packaging machine information database receives and processes reel data to provide real-time feedback for adjusting printing parameters, ensuring that customization flexibility does not compromise alignment precision.
2Adaptability or versatility
If digital printing modules are added for on-site printing, then customization flexibility is improved, but system complexity and data management challenges increase
Solution Approach 1:
The system introduces intermediary databases (printing information database and packaging machine information database) that act as mediators between the digital printing module and the packaging machine. These databases store and manage reel data, printing parameters, and machine settings, simplifying the interface and data flow between different system components. The intermediary databases handle data coordination, reducing the complexity of direct integration between printing and packaging systems.
3Manufacturing precision
If reel data is captured and transferred through multiple databases, then printing and packaging coordination is improved, but data transfer time and processing steps increase
Solution Approach 1:
The system performs preliminary data capture by extracting reel data from tags as soon as reels are loaded onto the packaging machine, before printing and packaging operations begin. This early data capture and storage in databases eliminates delays during production, as all necessary information is pre-available for coordinating printing and packaging operations.
Solution Approach 2:
The system maintains continuous data flow and processing throughout the packaging operation. Reel data is continuously transferred between databases and used in real-time to coordinate printing and packaging, ensuring that the useful action of data coordination continues without interruption or idle time, thereby minimizing overall processing time despite multiple database interactions.
Data Source
AI summary
A method for producing packages holding liquid food products from a web of packaging material, wherein the web comprises a number of blanks placed after one another, wherein each blank corresponds to one package, the method comprising receiving a reel holding the web of packaging material, capturing reel data from a tag attached to the reel, transferring the reel data to a printing information database, receiving printing information data (PID) related to the reel data from the printing information database, printing decors on each of the blanks of the web of packaging material based on information provided via the PID, transferring the reel data to a packaging machine information database receiving packaging machine information data (PMID) related to the reel data from the packaging machine information database, and forming the packages from the décor provided web in a packaging machine based on information provided via the PMID.