Upstream Printing Unit for High-Speed Container Labeling
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Solution Overview
Problem
Existing labeling systems for containers face inefficiencies due to the need to reduce machine speed when changing label rolls, leading to significant losses in system efficiency and difficulties in accessing and assembling digital printing systems, which increases installation and repair costs.
Innovation Solution
A device with a separate printing unit positioned upstream of the labeling unit, allowing for independent operation and enabling continuous high-speed labeling by decoupling the storage and labeling processes through a buffering device, and using an inkjet digital printing system for inline printing of self-adhesive labels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the printing system is integrated directly in the labeling unit, then the labeling process can be performed, but the machine speed has to be reduced when changing label rolls to ensure reliable adhesion, leading to significant loss of system efficiency
Solution Approach 1:
The system is divided into separate functional units: a storage unit for label rolls, a printing device positioned upstream, a buffering device, and a labeling device. This segmentation allows the printing operation to be decoupled from the labeling operation, enabling the labeling unit to maintain high speed during label roll changes while the printing device operates independently at its own optimal speed.
Solution Approach 2:
Labels are printed in advance on the label material while it is still on the roll, before the labels are actually applied to the containers. This preliminary printing action allows the printing process to be completed ahead of time, and the pre-printed labels can then be applied continuously at high speed without interruption during roll changes.
2Ease of manufacture
If the printing system is integrated in the labeling unit, then the labeling function is complete, but the printing device becomes difficult to access and assembly work is difficult, increasing installation and repair costs
Solution Approach 1:
The printing device is extracted from the labeling unit and positioned as a separate, upstream component. This extraction makes the printing device independently accessible for installation, maintenance, and repair operations, while the labeling unit can be serviced separately. The buffering device acts as an intermediary that connects these separated components without requiring complex integration.
3Ease of operation
If the printing device is arranged close to the labeling device, then the labeling process is streamlined, but the printing device becomes difficult to access for maintenance and assembly
Solution Approach 1:
A buffering device is introduced as an intermediary component between the printing device and the labeling device. This buffering device receives printed labels from the upstream printing device and supplies them to the labeling device, acting as a mediator that decouples the spatial arrangement. The printing device can be positioned upstream with easy access for maintenance, while the buffering device ensures continuous supply to the labeling process.
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
This configuration enhances system efficiency by allowing uninterrupted operation during label roll changes and simplifies maintenance by providing easier access to the printing system, reducing installation and repair costs while enabling flexible and precise printing of labels.
Implementation Method 1
a print head is used which uses an electrostatic print head with a large number of individually controllable individual nozzles for the controlled dispensing of printing ink
Implementation Method 2
an electrostatic print head with a large number of individually controllable individual nozzles for the controlled dispensing of printing ink
Implementation Method 3
labels are attached to an outer circumference of the containers, for example in the form of self-adhesive labels or with the aid of an adhesive
Data Source
Figure 1~2
AI summary
The invention relates to an apparatus (1) for labeling containers, comprising a storage unit (2), in which a supply of labeling material (10) is accommodated, a labeling device (8) which is disposed in the transport direction (T) of the labels and attaches the labeling material (10) onto the containers, and a print device (6), which provides the labeling material (10) with an imprint. According to the invention, the print device (6) is disposed in the transport direction (T) of the labeling material (10) between the storage unit (2) and the labeling device (8) and is positioned in the transport direction (T) of the labeling material (10) at a distance from the labeling device (8).