Labelling the efficient way

Labelling is playing an increasingly essential role in the current packaging climate. Labels must be aesthetically pleasing and sophisticated, but they should also play other roles, such as incorporating tamper-evident elements, Braille imprinting or RFID tags. Output is also important, and labelling systems must also be extremely efficient, being commensurate with other advanced packaging systems.

Avery Dennison, The Netherlands

Located in Leiden, Avery Dennison has launched a new direct thermal self-adhesive facestock that offers versatility, performance and enhanced label aesthetics. Fasson Thermal Top F8 is aimed at the broad food, logistics, retail and pharmaceutical markets for functional barcode labels. The facestock itself has exceptional functional qualities. It complies with the German BfR recommendation XXI for direct contact with dry, non-fatty foodstuffs, in addition to US FDA 175.105. It is resistant to oils, chemicals, heat, and UV light, being suitable for use in both freezing temperatures and warm bakery environments.

B & H Labelling Systems, USA

B & H Labelling Systems of Ceres, California has launched Marathon SLA, which is the latest addition to the successful Marathon series of roll-fed labellers. The Marathon SLA combines the field-proven Marathon SL technology with a complete Allen-Bradley drive-train and controls platform. The new Marathon SLA is designed for easy operation and maintenance, maximising reliability and uptime. Ideal for low- to medium-speed operations, the base Marathon SLA handles containers of up to 3 litres at speeds of 50 to 250 containers per minute (CPM), being capable of up to 450CPM, with added options.

Capsnap Europe, Austria

Located in Kremsmünster, Capsnap Europe has launched a special label for 5 gallon (18.9 litre) bottles that can be easily removed without leaving an adhesive residue. The innovative new lift label facilitates the quick, easy introduction of design changes. Furthermore, its pure polycarbonate formulation can be better recycled.

CFS, The Netherlands

CFS, headquartered in Bakel, has launched the first cross-web labeller in the world that operates entirely without machine interruptions. The design enables label reels to be changed whilst the machine is in operation. The fundamental advantage is the separation of label dispenser and applicator unit into two separate modules. The smooth servo-motor technology minimises tearing of label reels and the winding unit can accommodate reels with a diameter up to 500mm. Both factors contribute to higher line capacity. Furthermore, the CFS TiroLabelNT has a spring-loaded finger system. This enables special label shapes to be positioned quickly, securely and accurately on irregular surfaces at maximum cycle speed without damaging the packaging.

Ditone Labels, UK

In 2008, Braille printing will be at the forefront of development for Ditone Labels as all pharmaceutical packages must include Braille by 2010. John Haworth, Sales Manager, is a member of the British Standards Braille Panel PKW/0-02-F3 that prepared the UK standard DD264:2007 for Braille of Medicinal Packaging, published in 2008. He is regularly called upon to advise pharmaceutical companies. Ditone is also discovering that numerous other sectors are investigating the use of Braille labelling. In particular, producers of 'under-the-sink' and veterinary products are beginning to adopt Braille labelling.

This year, Ditone has launched the Braille Extensia Leaflet label. Extensia enables Ditone to combine a label and leaflet, which is very popular with those pharmaceutical companies that incorporate a large amount of text within the product. Screen-printing enables the Braille to be printed directly on the Extensia label, ensuring that all the required information is incorporated. The Extensia label constitutes just one simple packaging solution, thus reducing costs for the customer.

Domino, UK

Cambridge-based Domino has recently augmented its M-Series range of print and apply labellers with the launch of the innovative M500 linerless model. The elimination of backing for self-adhesive labels radically reduces waste. With up to 100 per cent more label material per roll than standard, the labeller can run for twice as long between roll changes. Further waste reduction is achieved by eradicating the matrix around each label.

Increased flexibility is ensured, as the M-Series Linerless cuts labels to the required size, thereby eliminating the need for changeover between products and consequently increasing productivity. An added benefit of producing different-sized labels from the same roll is that fewer variants in roll size are required, significantly reducing costs. Domino has partnered with materials suppliers to develop specialised substrates that are compatible with case material from a recycling perspective.

Fujicopian, UK

Fujicopian of Gillingham has launched a low-energy, yet high-perfomance thermal transfer film to the European market, designed for use on flat head printers.

The Fujicopian research and development department has made significant developments to the sub-layer component of the film. This is located between the carrier PET film and ink layer, determining the energy needed to release the ink to the label. These improvements in the layer formulation make the label thinner, requiring less energy to print.

With standard products, the sub-layer does not transfer, remaining on the carrier film. The FS4 sub-layer is specially designed to transfer and settle on the top of the ink, ensuring chemical 'encapsulation' of the print, hence achieving higher resistance. The FS4 can also contribute to energy savings, supporting corporations committed to cutting their power consumption and being used at a maximum printing speed of 16ins. (406mm) per second.

Gidue, Italy

In collaboration with Air Liquide, IST Metz, Softal and Sun Chemical, Turate-based Gidue has launched a joint project entitled UV Flexo for Food Packaging. The objective of this development is to offer a one-stop solution package for printing fully-certified, cost-effective flexible food packaging. The Gidue Athena digitally-controlled mid-web press is available in widths ranging from 530 to 730mm. It uses specific low-migration inks to ensure final food end-product safety and enhanced performance for UV curing and adhesion.

The press integrates Aldyne in-line plasma coating, eliminating such problems as poor ink adhesion and low print productivity. It implants reactive chemical groups on the film surface, creating chemical bonding between the substrate and ink. Gidue has recently promoted Food Contact Notification (FCN) 772, which has also been approved by the FDA. This facilitates direct food contact with UV- or electronic beam-cured formulations. FCN772 has been promoted by the Food Notification Alliance, which includes Gidue as the only labels and flexible packaging press manufacturer.

Harland's Labels, UK

Hull-based Harlands Labels has made a significant investment into its Polish facility. The company has doubled its production capacity, investing in such new equipment as an additional MPS press, applying ten colours with options for both hot- and cold-foil stamping. The company opened a second facility in Lublin to support existing customers who had relocated production facilities to Eastern Europe. The company's Polish facility mirrors its English one, ensuring that all labels are printed to the highest technical standards.

Harland's has also invested in the UK. Its range of Peel and Read labels, which have proved popular with such international companies as the Body Shop, have recently been augmented by the launch of a stepped Peel and Read label. This enables the customer to skip directly to the relevant page, thereby increasing functionality.

Industrial Labelling Systems, UK

Industrial Labelling Systems (ILS) of Middleton, Greater Manchester is primarily involved in the supply of the Swedish Mectec range of labelling systems. ILS supplies RFID labelling systems, A5-A3 Pallet Labelling, the unique TT-100 Linerless Labelling system and the giant T90 A3 print and apply system. It also offers a full range of thermal transfer ribbons. ILS has recently launched linerless outercase print and apply labelling systems. This eliminates the need for paper backing, thereby saving print time as label changeover time is halved, increasing label output and eliminating the need to hire specialist contractors to dispose of the backing.

ILS has recently installed three TT-150 print and apply labelling systems to the 2 Sisters Food Group production site in St Neot's, Cambridgeshire. The six inch (152.4mm) TT-150 labelling systems have been integrated with the Endoline 706 case taping system, resulting in a labelling and case taping solution within a very small factory footprint.

Kosme, UK

Kosme of Burton-on-Trent (part of Krones Group) offers a comprehensive range of modular labelling machines that can be easily converted to perform numerous functions using interchangeable attachments and 'future-proof' production lines.

Modular machines offer various plug-and-play options from a single base station chassis, incorporating a transport carousel mechanism. The chassis can be equipped with any number of label applications. The modular system is particularly useful when production lines apply a number of different product labels. One combination machine can perform the role of several independent machines. During bottling, for example, it is possible to realise a combination of multiple neck, back and body labelling positions using either wet glue or self-adhesive labelling.

Logopak International, UK

Five bespoke high-speed print & apply labelling machines have been installed by Cheshire-based Roberts Bakeries to enable individual loaves from different lines to be identified at a central point for either automatic or manual loading in trays. Supplied by York-based Logopak, the Series 515 machines print and apply small bar code labels measuring 50x50mm to loaves wrapped in branded film. However, larger labels carrying ingredients information are placed on loaves wrapped in plain film for the sandwich trade. Each machine can label up to 60 loaves per minute.

Space on the individual production lines is at a premium and labellers have thus been specially designed to operate from above, attaching labels to the top of each loaf. The blow-on label applicator has been designed to suit the application and is able to swing through 30°, following the loaves in continuous motion as the label is attached. Wilson Clark, General Manager, Logopak commented: "To achieve speeds of 60 loaves per minute, continuous motion is necessary, but there can be no pressure on the loaves, which are still warm. By matching the speed of the loaves, the applicator head ensures good adhesion without risk of damage."

Markem-Imaje, USA

Bakemark UK is the leading supplier of bakery ingredients and frozen bakery products in the UK. It has recently liaised with the international company Markem-Imaje, headquartered in Keene, New Hampshire, on a project to replace existing high-maintenance labellers. Bakemark established that over 92 per cent of the equipment investment will be offset by savings in consumables and downtime.

Bakemark now has five Markem-Imaje 2000 print and apply units, together with Markem-Imaje Crayon Large Character and Markem-Imaje Nova desktop printers operating at its production lines at Bromborough. Ian Hamer, Factory Service Manager, Bakemark UK explained: "We now print all the information required, including traceability and product identification codes, such as manufacturing date and time, production line number, batch number, product name, logo and barcode on a much smaller label. By using a smaller direct-transfer label, instead of the thermal transfer ribbons and labels used by the old printers, we achieve annual savings of almost £67,000 on labels and ribbons alone!" Furthermore, Bakemark UK applies almost 180 different label configurations with a selection of up to 20 varying templates. Markem-Imaje modified the application software to accommodate all possible variants. Users merely type in a simple three-letter code on the Markem-Imaje keypad to select any of the label configurations.

NSD International, UK

Exactly 150 years ago, Simpson Label Company of Dalkeith was founded to meet the insatiable demand from the myriad coal mines that surrounded Edinburgh. Every bag of coal required a tag, carrying the date, weight and the name of the colliery. The company was bought 25 years ago by the Dutch-based NSD International, still continuing to trade as Simpson Label Company, bringing to market the ground-breaking digital label just over a decade ago.

Simpson will now trade as NSD International, exporting its specialisations to other group companies to satisfy a fast-growing global demand. The Edinburgh operation will also benefit from NSD's other plants in Germany, the Czech Republic, Romania and The Netherlands. For example, NSD Edinburgh recently completed an important assignment for Glenmorangie involving a global repositioning of its whisky range. This necessitated the application of an incredibly complex suite of labels for the new sculptured bottle in larger volumes with up to 200 label configurations.

Pago, UK

Pago of Colchester launched its latest labelling technology at Interpack. The System Concept 100 presents economical facilities for all standard labelling tasks. However, the System Concept 500 provides solutions to high-performance customer requirements. The precision and flexibility of high-speed labelling has been demonstrated by the Pago Rotary System 630, utilising the latest generation of Pagomat automatic labelling machines. Pago has also developed linerless labelling systems - comprising high-quality product decorative labels without backing paper. In the identification sector, Pago has also pointed the way to efficient and progressive logistic solutions with the development of its new Pago software concept, RFID solutions and hardware range for every product identification task.

Royston Labels, UK

Royston Labels in Hertfordshire, the specialist, self-adhesive label manufacturer, has launched Ultra Clear. Manufactured from a unique combination of conformable polyolefin materials, the label is applied using an adhesive that is new to tubes, realising special 'no-look' label aesthetics. In fact, Ultra Clear imparts the illusion of invisibility, even on very dark surfaces, achieving the clarity of a directly-printed tube without detrimentally affecting design or print quality. It has a label thickness of only 46 microns, which is nearly half that of a standard label.

Sessions of York, UK

Sessions of York has also undertaken some development work in the wake of new European legislation regarding Braille labelling of pharmaceutical products.

The EU's recommendations for minimum dot heights range between 0.46-0.50mm on cartons and 0.25mm for label printers. However, it is not possible to realise print of this kind on most high-speed packaging lines, machines and materials. Accuracy is paramount - an incorrect or missing dot would necessitate complete product recall. Sessions of York has surpassed the EU's 2004/27 directives, achieving highly-accurate 0.37-0.4mm minimum dot heights on label presses at high speeds. Sessions undertakes printing on transparent filmic labels and the Braille dots are very precise. Sessions' 'Profile' Labels can provide a raised tactile image in Braille, Moon or large conventional lettering.

Systems Labelling, UK

Systems Labelling of Deeside, Flintshire is a strong player in the large volume flexographic label-printing industry. It manufactures products across a broad range of sectors. It has incorporated quality inspection technology, delivering quality control throughout the production process. The unique system records every label printed across its six 8-colour presses and dedicated slitter/rewinders. Any imperfection is marked within the software file and defective labels are removed prior to shipping. Systems Labelling believes that the 'golden rule is mono', offering three environmentally-friendly options manufactured from recyclable, biodegradable and home-compostable materials.

Videojet, USA

The Videojet DataFlex Plus is at the forefront of Thermal Transfer Overprinting (TTO) technology. In the past, it was considered that there was a maximum 1mm print gap between prints (the 'print gap' is the space found between prints when viewed on the ribbon). However, recent research has indicated that this information is incorrect - the actual print gap for the DataFlex Plus is a maximum of 0.5mm, without any loss of performance or print quality.

The patented ribbon design of the DataFlex Plus ensures a 0.5mm print gap, as there are no mechanical devices involved in the ribbon-drive process. Andy Millar, Thermal Transfer Product Manager for Europe, Middle East and Africa commented: "Videojet customers have been benefiting from the 0.5mm print gap in their production environments without actually realising it! For a typical printed image 10mm long, our customers will have been benefiting from a 5 per cent increase in production before replacing a roll of ribbon."

Weber Marking Systems, USA

Headquartered in Arlington Heights, Illinois, Weber Marking Systems launched a new label printer-applicator at Interpack 2008. The Model 5300 Series features numerous enhancements and innovations to provide maximum flexibility and versatility for end-users. It combines modular design with high-speed, high-quality label printing, application and optional RFID encoding.

Due to its modular design, the new model can offer six different pressure-sensitive label application methods - air-blow, tamp-blow, direct-tamp, corner-wrap, swing-tamp and two-label/adjacent panel printing. The 5300 can thus be reconfigured to meet future labelling requirements without the need to acquire a separate printer-applicator.

Concluding remarks

Three factors are stimulating change in the labels and labelling world. Of course, the environment has a role to play, influencing materials choice and development. New EU legislation regarding Braille labelling is requiring the use of special label types and application machines. Finally, both labels and labelling machines must exhibit performance commensurate with that of the remainder of the high-speed packaging line.

Note

Please note that many product and machinery names are trade marks or registered trade marks and should be treated as such.

For more information, go to www.averydennison.com; www.bhlabeling.com; www.capsnap.at; www.CFS.com; www.ditone.co.uk; www.domino-printing.com; www.fujicopian.co.uk; www.gidue.com; www.harlands.co.uk; www.ilsystems.co.uk; www.kosme.co.uk; www.logopak.com; www.markem-imaje.com; www.nsdinternational.com; www.pago.co.uk; www.roystonlabels.co.uk; www.sessionsofyork.co.uk; www.systemslabelling.com; www.videojet.co.uk and www.webermarking.com

The M500 linerless print and apply labeller from Domino No liner required Industrial Labelling Systems supplies the Swedish Mectec range of labelling systems Swedish speciality Five Logopak Series 515 print & apply labelling machines have been installed at the Cheshire-based Roberts Bakeries Optimising the efficiency Pago has developed linerless labelling systems that comprise high-quality product decorative labels without backing paper Enhancing shelf-presence Sessions of York has developed innovative methods of applying Braille to pharmaceutical labels Braille labels