Professional Documents
Culture Documents
12
Manufacturing developments
12
13
Paper additives:
14
Metallised paper
15
15
17
Functions of a label
19
20
22
23
23
24
25
28
30
33
Objective
36
39
41
44
46
49
51
54
56
Pulped labels:
56
57
Common adhesives:
59
Advantages
59
Disadvantages
59
Advantages
59
Disadvantages
59
Advantages
60
Disadvantages
60
Characteristics of adhesives
60
61
62
62
65
Types of lasers:
66
69
70
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Ink cabinet
71
Print head
72
74
75
77
Videojet maintenance
78
Shutdown procedure
78
79
80
80
80
Phasing faults
80
81
Safety ________________________________________________________________________________________________83
Objective
83
84
93
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Objectives
Having completed this course the student should have achieved the following objectives:
Development of paper
Development of printing
Features of a label
Paper manufacturing
Functions of a label
Types of container
Labeller manufacturers
The magazines
Aggregate adjustments
Label removal
Label adhesives
Storage of materials
Safety
Page 5 of 98
Development of paper
Objective
To discuss the history of labelling and the development of labelling machines
Once mankind developed farming skills and was able to construct buildings, people settled
in villages and small communities, and later towns and cities. Trade between communities
and nations became widespread as different communities specialised in producing
particular items or raw materials.
The need arose for the identification of products. Archaeological remains show that many
trade commodities- oil, wines, spices, dyes etc.. were identified by means of inscriptions
on clay tablets, or by inscriptions directly engraved on clay pots, identifying the product
and where it came from.
Before the invention of paper, various cultures used different materials to record written
information. Stone, metal, wood, papyrus, clay, parchment, vellum, cloth, tree leaves, bark,
and rice-pith "paper" have all filled this role at one time or another.
The Sumerians, who inhabited southern
Mesopotamia , first developed writing in the form of
pictographs around 4000 B.C. Since clay was
readily available in the region, it was used as the
writing surface. By around 3000 B.C., the
pictograms had evolved into wedge-shaped
characters that were drawn with the edge of a
stylus.
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Papyrus, made from reeds, has played an important role in history. The oldest written
papyrus rolls date back 5000 years, and the word "paper" itself is derived from the
Greek and Latin words for papyrus.
AD 105 is often cited as the year in which
papermaking was invented. In that year,
records show that the invention of paper
was reported to the Chinese Emperor by
Ts'ai Lun, an official of the Imperial Court.
Early Chinese paper was probably made
from a suspension of hemp waste in
water, washed, soaked, and beaten to a
pulp with a wooden mallet. A paper
mould, probably a sieve of coarsely
woven cloth stretched in a four-sided
bamboo frame, was used to dip up the
fibre slurry from the vat and hold it for
drying.
Chinese papermakers also spread their craft into Central Asia and Persia, from which it
was later introduced into India by traders.
Papermaking spread to Baghdad in the 8th century AD and into Damascus, Egypt, and
Morocco by the 10th century.
It took nearly 500 years for papermaking to reach Europe. Although the export of paper
from the Middle East to Europe began in the 10th and 11th centuries, the craft was
apparently not established in Spain and Italy until the 12th century.
Early paper was at first disfavoured by the Christian world as a manifestation of Moslem
culture, and a 1221 decree from Pope Frederick II declared all official documents written
on paper to be invalid.
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Development of printing
Objective
To explain the origins of printing.
In the early 1450's rapid cultural change in Europe
fuelled a growing need for the fast and cheap production
of written documents. Johannes Gutenberg borrowed
money to develop the printing press.
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The ideal label is one that looks attractive and persuades the consumer to buy the product,
handles without problems on the labelling machine, and remains firmly bonded to the
bottle throughout its useful life.
A good label paper has certain ingredients and possesses various characteristics which
include:
Features of a label paper
Caustic resistance and Caustic permeability
Mechanical strength and tear strength
Flexibility
Correct size and design
A smooth front finish and a rough rear finish
Water absorption (Cobb value)
Curling tendency / Grain Direction
Adequate grammage
Ash content
Brightness
Page 9 of 98
Caustic resistance and Caustic permeability: Labels should be slightly resistant to the
action of bottle washing detergents, specifically caustic, to prevent the label paper fibres
being reduced to a pulp and contaminating the washing solution. They must however be
permeable to caustic, so that it can penetrate the label and dissolve the glue.
Mechanical Strength (Tear Strength): This refers to the amount of force required to
continue tearing an initial cut in a single sheet of paper. High speed labelling subjects the
label paper to mechanical stresses, thus the degree of tear strength must be sufficient to
prevent damage and tearing during label application, particularly when gripper cylinders
remove the label from the pallet.
Flexibility: This is the ability of the paper to curl sufficiently enough to fit the curved
surface of the bottle.
Correct Size and Design: Cutting of the labels by the printer to the correct size and shape
ensures uniformity of the labels when glued to the containers. Labels cut to the wrong size
will cause feed problems in the magazine.
Surface finish: Ideally label paper is smooth on the front surface, so that the printing and
design features present an attractive visual appearance, and it is rough on the reverse
side. This is particularly important when labelling wet bottles, as a rough paper with the
correct Cobb value absorbs water more quickly than a smooth paper surface, and so
prevents the labels from skidding on the containers.
Absorption (COBB value): The amount of moisture absorbed by one square metre of
paper in a specific time is called its Cobb value. To create a bond between the label and
the container, the moisture content of the glue must be reduced. The paper absorbs the
moisture from the glue, leaving behind the glue solids which form the adhesive layer that
binds the label to the container.
The quicker the paper absorbs the moisture, the quicker the glue solidifies, giving a secure
label.
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Curling Tendency / Grain Direction: This refers to the curling property of the paper
under variations in heat and humidity. One of the ingredients of label papers is cellulose
fibre. These fibres should all lie in one direction, which is called the grain of the paper.
When absorbing or losing moisture, paper fibres contract or expand in one direction only,
which causes the paper to curl.
A simple way of checking the grain direction is
to moisten the back of the label with water
and note the direction of the curl. If it curls
from top to bottom, it is correct for labelling
application. Once labels have curled, they
cannot be used, as the fibres, swollen with
moisture, dont return to their original size
even when dry. Labels with too little moisture
on the other hand, dry out, shrink in size and
loose their tensile strength. It is thus essential
to store labels under the correct humidity
conditions.
Grammage: The mass or weight of a measured size of paper expressed in grams per
square metre.
ASH content: If a label is burnt, the residue left is the ash. Inorganic matter such as china
clay and other filling agents, make up this ash. A good label paper has an adequate
balance of organic material, like wood or sugar cane fibres, and inorganic ash materials
like fillers.
Brightness: The amount of light reflected by the paper.
All of the above features are combined by the paper manufacturer to produce a suitable
paper for labels.
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Paper manufacturing
Objective
Describe how coated and metallised paper is manufactured.
Manufacturing developments
The principles used to make paper by the Chinese are not that different from the
processes of today. Preparing the stock, forming the paper web, drying the sheet, and
applying coatings and additives are the basic steps of paper making that have remained
unchanged.
Paper is principally made from Cellulose fibres. There are various sources of such fibres
which include wood and sugar cane.
European papermakers used cotton or linen fibre from rags. The rags were heated in a
solution of alkali, then washed and mashed to a pulp, which was then bleached to remove
the final traces of any dyes.
In 1798, the Frenchman NicholasLouis Robert invented a machine on
which paper was formed on a
continuous sheet of wire cloth.
European papermakers were the first to use watermarks. An offshoot of the guild system,
the watermark served as a means of identifying the paper with the members of the trade
organisation who manufactured it.
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The individual cellulose fibres are still hollow and stiff, so they are broken down to help
them stick to one another in the paper web. This is accomplished by "beating" the pulp in
the refiners, vessels with a series of rotating sharp metal disks.
Once the pulp has been bleached and refined, it is rinsed and diluted with water, and
fillers such as clay may be added. For label paper a resin is included to give wet
strength.
This solution is pumped into the headbox of the paper machine and is dispensed onto the
wire, a moving continuous belt of wire or plastic mesh. As it travels down the wire, much of
the water drains away or is pulled away by suction from underneath. The cellulose fibres
trapped on the wire stick to one another to form the paper web. From the wire, the newly
formed sheet is transferred onto a cloth belt (or felt) in the press section, where rollers
squeeze out much of the remaining water.
After leaving the press section, the sheet reaches the drying cylinders. These are large
hollow cylinders, heated internally, which dry the paper as it passes over them. The sheet
will be wound up and down over many cylinders in the drying process. Between dryer
sections, label paper is coated with starch additives to improve the surface smoothness.
China clay will normally be added to increase the brightness of the paper.
Following another round of drying, the paper sheet is passed through a series of polished,
close-stacked metal rollers known as a calendar where it is pressed smooth.
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Finally, the sheet is collected on a take-up roll and removed from the paper machine.
Paper additives:
Binders: Starches that improve the strength or flexibility of the paper.
Sizing agents: Resins that coat the paper and control the absorption of moisture.
Pigments: China clay increases the brightness of the paper.
Page 14 of 98
Metallised paper
Often labels are printed on an embossed metallised paper which gives the product an
attractive image. The process of manufacture is the same as for coated papers, until the
metallisation stage.
The coated side of the paper is given a final very smooth
coating and covered with a primer lacquer, and dried to
eliminate 99% of the moisture. It then passes on a roller
through 2 vacuum chambers where pure aluminium wire is
vaporised at 250C. The paper passes over a chilled roller
where the aluminium vapour condenses, depositing an ultra
thin layer of metal onto the paper.
Page 16 of 98
Functions of a label
Objective
To describe the functions of labelling.
Originally labelling was used solely for the purpose of identifying a product.
In the modern world labelling is a sophisticated way of not only identifying the product but
selling the product as well. Labels have to comply with various legal requirements such
as a list of ingredients, the place of origin, the date of manufacture and freshness, and
often directions for use as well.
A label therefore is more than simply an
identification or decoration, it is also
informative.
With dangerous or poisonous substances
warning messages have to be included.
In some cases labels have a religious
function, identifying those products that are
Kosher or Halaal, and can therefore be safely
utilised by consumers without breaking the
dietary laws of their particular faith.
Page 17 of 98
The purpose of labelling or package decoration is to attract maximum attention from the
consumer.
There is no doubt that effective labelling increases sales and when this is linked with
other forms of advertising in the press, radio or television, the image of the product is
strengthened.
Building a long term brand loyalty with the consumer is one way of ensuring market share.
In order to accomplish this, a product must be instantly recognisable by its appearance,
i.e. its package and label decoration. Changing a label or package design can have
serious negative effects on sales, if consumers believe that the product has changed in
some way.
Much research goes into the design of packaging and labelling to fulfil the marketing
objectives, and many ingenious ideas to increase sales and brand awareness are evident
on the store shelves.
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Functions of a label
Functions of a label
Example
Identifies product
Heineken
330 ml
Advertises product
Appeals to consumer
Product of APB
Identifies ingredients
Alcohol 5% by volume
Page 19 of 98
Types of container
Objective
Identify common containers used in beverage packaging.
The type of label that is used is very much dependent on the container that is being used.
There is a wide range of different containers and packaging materials in use today:
Glass Bottles
Plastic bottles
Plastic drums
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Labelling technology caters for almost every shape of container, round, square,
rectangular, and every size from vials to kegs and crates.
A major consideration that often determines the type of label to be used is the type of
container. Labels can be paper, metallised or plastic.
Glass bottles are most often labelled with paper labels, but metallised labels can be
used, as can self adhesive labels which are made from a plastic laminate, or aluminium
foil.
This neck label is an aluminium foil label
Rigid substances such as glass, ceramics, metal or hard plastics retain their shape and
the label can be pressed on. Soft plastics, PET, polystyrene, PVC and cardboard have to
be handled with delicacy to prevent distortion or breakage.
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In the beverage industry cans are normally pre-printed for the product that they contain,
and no label is applied. In the food industry the food is canned when crops of fruit or
vegetables are harvested and labels applied afterwards.
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Odd shaped containers such as the square bottles below are normally labelled in-line
and only ever conveyed in single file.
The label is a plastic pressure sensitive self adhesive label on a wax paper backing roll.
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Labeller manufacturers
Objective
Name 4 labeller manufacturers.
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Page 29 of 98
The infeed conveyor supplies filled and pasteurised bottles to the labeller.
The discharge conveyor conveys the labelled bottles to the packer.
The bottles are separated by the infeed worm so that they are at the same pitch as the
infeed star wheel. The infeed star wheel transfers the bottles into the labeller, the spacing
on the star wheel being equal to the pitch of the labeller bottle transfer.
Page 30 of 98
The infeed conveyor is fitted with an inductive or capacitive sensor (gap detector) that
stops the machine if there are no bottles present, or if there is a fallen bottle. A reset
button is provided to reset the sensor once the problem has been corrected. The sensor
also acts as a missing crown detector, so that any bottles with missing crowns will stop the
machine and can be removed.
The bottle stop is a small star wheel situated in the bottle side guide rail of the infeed
conveyor. The bottle stop will rotate and allow the bottles to pass during normal running.
When the flow of bottles to the infeed is to be stopped, an air cylinder is selected to lock
the bottle stop which will stop rotating and hold the bottles back.
When the flow of bottles is to continue the air cylinder is selected to retract and allow the
bottle stop to rotate and the bottles will pass into the infeed.
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Bottles are transferred to the labeller via the infeed star wheel and intermediate star wheel,
and then to the labeller bottle pads.
Once labelled, the discharge star wheel transfers the bottles to the discharge conveyor.
Underneath the star wheels are plates which support the bottles and are important in
achieving a smooth transfer. The height of the transfer plate and the conveyor or bottle
table must be the same to ensure that the bottles transfer smoothly into the machine.
Page 32 of 98
There are normally either one or two aggregates on a labeller, an aggregate can apply
more than one label. Having more than one aggregate also makes the operation more
flexible in terms of changeovers and the number of labels that can be applied by one
machine.
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On Krones machines the body and neck labels are applied first, on KHS machines the
back label is applied first.
The aggregate is shown below when viewed from the top.
The collection of parts shown below is known as an aggregate. It consists of a gearbox,
pallet turret, gripper cylinder drive, glue roller drive and label magazine mounting points.
The entire aggregate can be moved in and out relative to the machine centre (radial
adjustment), and side to side relative to the machine centre (tangential adjustment).
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Aggregates have either a rubber glue roller with steel pallets, as below, or a steel glue
roller with rubber coating .
Steel glue rollers are a fairly recent development (last ten years). They allow more
accurate glue film thickness control, and are less susceptible to damage if a stray label is
lodged under the scraper blade.
The glue roller is a cylinder which mounts on the roller drive shaft and rotates on it. The
drive shaft has a key which locates in the slot in the roller.
The glue roller retains a film of glue on its surface which coats the glue pallets with a film
of glue. The glue on the roller is supplied from the glue pump through the glue nozzle
which is mounted on the glue scraper assembly.
The scraper blade presses very close to the glue roller to make sure that only a thin film of
glue is transferred to the pallets.
When no bottles are being labelled, the scraper blade is pushed hard against the glue
roller by a solenoid unit. This ensures that excess glue does not build up on the pallets if
the machine is left rotating.
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When bottles enter the machine, the solenoid is retracted, and the glue film thickness
depends on the setting of the vernier screw shown below:
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The pallets
Objective
To describe the purpose of pallets in a labeller.
The pallet turret consists of the turret base and sockets, the glue pallet shafts with their
pallets, and the turret cover.
The turret base houses the pallet sockets. The pallet shaft drive ends slot into these
sockets. Always ensure that the pallets match up to their numbered markings on the base
and that the pins in the sockets line up with the slots in the pallet shafts.
Socket number
Pallet shaft
The purpose of the pallets is to collect a film of glue from the glue roller, pick up a single
body label (and neck label) from the magazine with the film of glue which will be
transferred to the labels and then position the labels so that the gripper fingers can remove
the labels from the pallet. (Or to pick up a back label in the case of the pallets on the back
labelling station).
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The cut outs in the pallet allow for the pallet to pick up a label from the magazine, and to
transfer it to the gripper cylinder, without the pallet touching the magazine or the gripper
finger.
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The magazines
Objective
Name and describe the function of label magazines components
The label magazines are mounted on the label carriages and are held in place on the
mounting bars by the magazine mounting clamps. The purpose of the magazine is to
store a supply of labels to be picked up by a glue pallet on demand.
The magazines are made up of the following components:
The magazine body
The mounting clamps
The label guides
The slide tensioner
The fingers or prongs
The magazines have a piston underneath the magazine carriage, that pulls the magazines
away from the carriage when labels are not needed, and brings the carriage into the
aggregate as bottles enter the machine.
Page 41 of 98
The magazine fingers are adjustable to provide equal pressure on the labels at all points,
and must be positioned within the pallet cut-outs so that the fingers do not touch the
pallets.
The sensor on the infeed star wheel controls the operation of the carriage:
Page 42 of 98
A delay timing device receives a signal from the sensor, then activates the air supply to the
magazine carriage so that the magazine moves in to the path of a glue pallet, a label is
transferred to the pallet, from the pallet to the gripper cylinder, and from the gripper
cylinder to the first bottle that enters the machine.
Incorrect positioning of this sensor will lead to either the first bottle having no label each
time that the bottle stop opens, or else to there being an extra label on the pallets each
time the bottle stop opens.
This extra label normally finds its way under the scraper blade against the glue roller.
The construction of the magazine can help to prevent the wrong position (e.g. upside
down) of labels especially those with a symmetrical shape like body label. (It's a good idea
that body or shoulder label should have a cut slot on the label or applied colour on one
side of a stack of labels to prevent reverse or upside-down loading of labels into
magazine).
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The gripper cylinder fits onto a hexagonal shaft, but the shaft is cut asymmetrically, so that
there is only one position that the gripper cylinder fits on. For this reason it is necessary to
rotate the gripper cylinder when fitting it to the shaft.
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When the gripper cylinder is installed it is important that the cam control arm is located in
the slot to stop it rotating.
Also note the white spacer that has been fitted onto the shaft below the gripper cylinder.
It is only possible to remove or fit a gripper cylinder if the aggregate has been pulled out
from the machine. If the aggregate has not been pulled out, the gripper cylinder will collide
with the top of the machine frame when you try to lift it off of the shaft.
Page 45 of 98
The bottle table is the rotating base of the machine which carries the bottles past the
labelling station and through the brushing station to the discharge.
Mounted in the bottle table are the bottle platforms. The bottles stand on the bottle
platforms and are rotated by gears in the bottle table.
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The centering bells push down on to the bottles from above and hold the top of the bottle
in place. The dished washer at the top will stop the machine (by activating a sensor) if the
bell is suddenly released, such as when a bottle has burst:
Once the label has been applied to the bottle by the aggregate, it passes through several
brushing stations which brush the labels onto the bottle so that they cannot come loose.
The body and neck brushes brush on the body label and commence the brushing of the
neck foil (This is how your brushes SHOULD look !!).
Where foil labels are applied, then towards the discharge the bottle is rotated to brush one
side of the foil completely around the neck (The correct positioning of these brushes is
critical, a fraction of a mm can tear the foil or cause creasing:
The discharge star wheel is fitted with rollers that cause the bottle to rotate whilst in the
star wheel. A set of brushes mounted over the star wheel ensures that the foil is brushed
completely in place all around the bottle
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Aggregate adjustments
Objective
To explain the mechanical adjustment of the labelling station.
Adjustments that can be made by the labeller operator at the aggregate are:
Glue film thickness on the glue roller
Glue temperature
Glue pump delivery rate to the glue roller
Aggregate radial position
Aggregate tangential position
We shall look at these in two groups, those relating to glue and those relating to the
aggregate position:
Glue film thickness on the glue roller
Glue temperature
Glue pump delivery rate to the glue roller
These adjustments are made at the glue pump and glue roller scraper blade.
The glue film thickness adjustment is probably the
most basic and important adjustment that the
operator makes. It is essential that the glue film is
thin enough to allow for fast drying of the glue (or
else the label is damaged on the conveyors) yet
thick enough to secure the label properly. A
vernier screw is normally provided as shown here,
which when screwed clockwise moves the scraper
away from the roller and thus gives a thicker glue
film.
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If the lines join up with no gaps between the glue is too thick. If the lines break up the glue
is too thin. Adjustments are made at the glue scraper blade as shown above.
Some labellers now have a split scraper blade, that allows a separate adjustment of the
glue film thickness at the top and bottom of the glue roller. This allows a thin film of glue to
be applied to the body label and a thicker film of glue to be applied to the neck label, which
is often necessary to spread the glue out to the outer corners of the neck label and stop it
becoming loose.
The amount of glue delivered by the glue
pump to the scraper blade is adjusted at the
glue pump. The glue pump is air operated,
with the air being used to perform up and
down strokes of the pump. The speed of
each up or down stroke is adjusted with a
small exhaust valve.
If the pump runs too fast then the glue will be
pumped to the scraper blade and back to the
glue drum many times, which can lead to the
glue breaking up and becoming lumpy.
If the pump runs too slow then there will not
be sufficient glue at the scraper blade and all
of the labels will fall off of the bottles.
The correct pump speed is checked by the
amount of glue delivered to the roller, and
with the labeller running only a little glue
should flow back to the glue drum.
A correct stroke speed is normally similar in speed to the ticking of a clock, i.e.: about 1
second per stroke.
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Glue temperature is indicated on the glue pump pipe, and is adjusted at the glue heater.
The temperature affects the glues viscosity. Too cold and the glue will not spread
properly, too hot and it will dry and fly off the pallets making the labeller dirty. Whilst
Casein glues can operate at 20 to 29C, 25C is probably a good target.
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The mounting plate can be moved in two directions. The mounting plate is often referred to
as the cross slide.
The cross slide moves in and out, closer or further from the centre of the labeller. This
adjustment has 2 functions. It allows for different sizes of bottle diameter to be labelled,
and secondly the cross slide is pulled out to allow for the removal of the gripper cylinder.
The cross slide also moves from side to side, i.e. at a tangent to the bottle table. This
adjustment changes the point at which the label is pressed on to the bottle by the gripper
cylinder.
On the aggregate the locking clamp must always be released (turn anti- clockwise) before
moving the aggregate in either direction and re-tightened (turn clockwise) after the
adjustment is complete.
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The aggregate position (on Krones Prontomatic labellers) when fully inwards is determined
by a rotating stopper device. Different screws of different lengths allow different bottle
sizes to be accommodated.
The handle shown below is turned to move the aggregate from one side to the other,
which changes the point that the gripper cylinder presses on the labels.
The aggregate is moved tangentially to the bottle table.
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Adjustment of the aggregate tangential position is probably the one adjustment that
operators have the most problem in understanding, as it is very difficult to see the effect,
and many operators think that skew labels are caused by brushing adjustments. A quick
check is to view the aggregate from above, and if correctly positioned there should be a
straight line between the centre of the machine, the centre of the bottle, and the centre of
the gripper cylinder.
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On KHS labellers, the tangential position of the aggregate can only be adjusted from
underneath the machine.
For radial adjustment the
aggregate swings away from the
machine by releasing the locking
clamp and then the aggregate
moves on a circular slide. Stopper
screws as shown here mark the
correct position for different bottle
sizes.
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It is essential that labels are removed from the washer detergent solution intact. The label
must be permeable to the caustic soda, so that it can penetrate the label and dissolve the
glue holding it to the bottle.
At the same time the label must resist being broken down to a pulp by the caustic soda.
The strength of the pumps extracting the caustic and pumping it to the label drum must
also be set so that it is sufficient to pull the labels towards the drum, but not strong enough
to break them up.
If the labels start to break up they are said to be pulped
Pulped labels:
Inhibit washing efficiency.
Shorten the useful life of the washing detergent.
Clog washer jets & pump strainers.
Cant be removed from the detergent.
Leave deposits on the bottle.
Can be seen as small fibres floating in the product.
It is also important with
metallised labels that the ink
remains on the label.
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Label adhesives
Objective
Know suitability conditions of glue for labelling
Identify quality criteria of glue for labelling.
Identify the advantages and disadvantages of starch, dextrin, and casein-based glue.
Identify 6 characteristics of glue.
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Glue consists of a liquid, usually water, or a solvent, with additives to give it good adhesion
and bonding properties. These include various proteins and solids. When glue is applied
the water or other liquid solvents evaporate or are absorbed into the label paper. The solid
particles draw closer together as the glue dries and form the adhesive bond between the 2
surfaces.
During labelling, glue needs to dry quickly,
but must also flow easily and at high speed
onto the pallets. To liquidise the glue so that
it flows easily over the glue roller, pallets and
label surface we heat it with a glue heater.
In the tropics a glue cooler is used.
The correct choice of adhesive is vital for
operational efficiency and economy. The
type and grade of adhesive, operating
temperature, glue film thickness, container
material and the label paper all influence the
labelling process.
Adhesives are classified according to the raw
materials from which they are made. Specific
adhesives are formulated for different
purposes
Page 58 of 98
Common adhesives:
Starch
Dextrin
Casein
Modified Casein
Synthetic
Hot melt
Starch based adhesives: A suspension of starch granules in water, with additives of resins
etc.. Often made from animal waste.
Advantages
Disadvantages
Good machinability
Clean running
Disadvantages
Low solubility
Unsuitable for coated glass, plastic and
metal
Page 59 of 98
Casein based adhesives: Made from milk protein with additives to enhance bonding
properties, solubility, tack, stability and shelf life.
Advantages
Disadvantages
Adjustable viscosity
Temperature sensitive
Difficult to clean
Destroyed if frozen
Characteristics of adhesives
Wet gluing capability: The ability of the glue to bond to wet containers.
Ice proof capability: Withstands low temperatures and extreme moisture, as is found in a
fridge. Ice-proof is tested by placing a labelled bottle in a bucket of water that is ice cold.
Every hour the bottle is turned 180 degrees by hand, until the labels fall off. 24 hours iceproof ability is a very good standard.
Viscosity: The thickness of a glue, its ability to be poured. The viscosity of a glue
decreases as it is heated.
Temperature: Glue becomes more liquid when heated.
Specific adhesion: This is the ability of a glue to adhere to a perfectly smooth surface. The
bond formed between the label and the container depends on the specific adhesion
qualities of the glue and its ability to wet and spread over the 2 surfaces. Slightly rough
bottle surfaces provide a mechanical anchorage for the glue, which strengthens the bond.
Casein based adhesives are most commonly used for returnable beverage bottling
applications, where paper labels are applied to glass bottles. Casein glues are suitable for
wet containers, but the label paper must have the ability to absorb excess moisture from
the bottle surface. Casein glues work best at 20 to 29C.
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Storage of materials
Objective
Identify 5 good practices for proper storage conditions of labels & glue.
Humidity: Labels should not loose moisture during storage. Dried out labels become stiff
and brittle, loose their tensile strength and tend to wrinkle when applied to containers. The
ideal storage humidity for labels is 60-70%, which is similar to the humidity conditions
found in the packaging plant. Labels which absorb moisture tend to swell excessively and
do not return to their original size when dry.
Temperature: An ideal range of between 18 and 22C should be maintained to prevent
wrinkling and distortion of labels.
Repacking: Labels must remain in sealed bags or cartons and only be removed when
required to feed the label magazines. Repack unused labels in moisture proof bags
immediately after shift end or brand change.
Stock Rotation: Practise correct stock rotation, first in, first out. The older a label is, the
more problems are likely to be experienced. Ensure that label stock levels are adequate
but not excessive.
Casein glues should be stored at 20-25C. The glue drum must be closed after use to
prevent drying out, and to keep out bacteria. Maximum storage time is 4 months as the
glue is made of milk proteins.
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Applying a production date or a consume by date is often a part of the labelling process.
The various methods of dating used are:
Methods of date coding
Codedge
Inkjet
Laser
The Codedge method, though crude, is still in use in many African breweries. Grooves are
cut into the side of the label, the position of the grooves indicating the production date.
The grooves can only normally be read with a codedge card. Some labels have a scale
printed on them so that the use-by date can be read from the scale according to where the
cuts are made, so that a codedge card is not needed.
Here a code has been
marked on the label that
can only be read with a
codedge card. This does
not allow the consumer to
know the production or
consume by date of the
product.
Inkjet date coding is very popular as it can be applied to labels, glass, plastic and various
other materials, and is a non-contact form of date coding.
The Videojet Excell range of date coding machines is very popular, and can be used for
cans or bottles.
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Laser dating systems are becoming increasingly popular due to their neatness and
accuracy in date marking the label.
Carbon Dioxide type lasers are usually used, so a bottle of CO2 has to be attached to the
machine, and a cooling unit is also necessary.
Apart from a little CO2, the lasers should then require almost no maintenance, and can
operate at extremely high speeds.
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Carbon dioxide based Laser dating machines cost about three times as much as an inkjet
dating machine. The running cost of a laser is MUCH less than the running cost of an
inkjet dating machine.
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Lasers have a pair of mirrors at each end of the lasing medium. The mirrors reflect
photons back and forth to increase the emission of photons from the medium. One of the
mirrors is half silvered to let some light through, which is the laser beam that is emitted.
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Types of lasers:
Solid State Lasers: e.g.: Ruby Lasers, the first Lasers invented used a ruby crystal as the
lasing medium.
Exciter Lasers: Use reactive gases such as Chlorine, mixed with inert gases such as
Argon to produce ultraviolet light.
Dye Lasers: Use complex organic dyes in a liquid solution, and can be tuned to produce
different light frequencies.
Semiconductor Lasers: Low power units such as used for light pens or CDRom readers.
Gas Lasers: Helium and Neon gas lasers produce visible red light. CO2 lasers produce
light in the far infrared range and are used for cutting and machining materials
CO2 lasers
It is the CO2 lasers that we are concerned with, as these are the type used for label
coding. CO2 lasers can be extremely dangerous because the light emitted is in the infrared
and microwave region. The laser beam cannot be seen. When used for cutting steel an
infrared Laser MELTS through the steel.
Lasers used for label coding are not as powerful as those used for cutting steel, but they
are still more than capable of burning a hole through the retina of your eye in a
microsecond.
Lasers are classified according to the damage that they can do to you.
Class I
Harmless
Class IA
Class II
Class IIIA
Intermediate power
Class IIIB
Moderate Power
Class IV
High Power: Hazardous under any conditions, a potential fire hazard and
skin hazard.
If you have Laser coding machines the class of the Laser will be clearly marked. As a CO2
laser they will be either class IIIB or IV.
It would be wise to remember that the most powerful lasers used in star wars research
are pulsed CO2 lasers.
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Using infra-red like the steel cutting Lasers, label coding CO2 lasers melt away the top
layer of ink on a label, exposing the colour of the paper below. They make an extremely
neat presentation, as shown here. In this case a white paper label has been printed with a
gold panel for the date.
The letters 11.00 L:615101K were burned onto the label by a laser coding machine. The
gold ink is instantaneously melted away to reveal the white base colour underneath. The
finish is neat and the quality is similar to that of the printing.
An electro-mechanical device contains copper masks which block the laser beam and form
the letters. The masks are moved by the control computer according to the date and time.
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Ink cabinet
The ink cabinet is also known as the hydraulics compartment.
Next to the ink cabinet is the pneumatics compartment, and above it is the electronics
compartment.
Inside the pneumatics compartment you can see the dosing pump and the reservoir:
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Print head
The print head is mounted either on the back label aggregate of the labeller or on the
discharge conveyor.
The print head is secured inside a protective sleeve by a single screw:
Photocells mounted on the labeller or conveyor signal the print head as to when to print
the date on the labels:
The picture below shows the delicate construction of the coding head.
It must be handled with great care and not exposed to water or shocks.
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Ink flows from the supply bottles of ink and make up fluid to the ink module.
The ink module mixes the correct ratio of ink and make up fluid to achieve the correct
viscosity for the ink.
The ink module contains a pump, which pumps the ink to the ink supply cylinder.
The ink supply cylinder is a reservoir with a magnetic float that ensures a constant supply
of ink to the print head. The ink supply cylinder is pressurised with air from the ink
pressure regulator.
The ink flows from the ink supply cylinder to the print head, where only some of the ink is
applied to the labels.
Ink that is not applied to the labels is collected in the ink return block of the print head, and
returns to the ink module and back to the ink supply cylinder.
The components can be identified below:
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During set-up of the machine, the nozzle crystal is adjusted to ensure a clean break of the
ink drops. A small red light below the ink stream acts as a strobe, so that with the help of a
magnifying glass the technician can accurately set the ink stream.
The ink drops now pass into the charge tunnel. The printer sends positive electrical
impulses to the charge tunnel, synchronised with the nozzle crystal so that the tunnel is
charged as an ink drop arrives.
The positive charge of the tunnel strips excess electrons from the ink drops, so that each
ink drop leaves the charge tunnel with a negative charge.
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The deflection plate is positively charged, and deflects the negatively charged ink drops
upwards. The amount of upward deflection is controlled by the size of the charge applied
in the charge tunnel.
Those ink drops that have no charge, carry straight onwards, enter the ink return block and
return to the reservoir.
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Each printed character is made up of a matrix of 5 dots across and seven high.
The electrical charge on the ink drops determines their height on the matrix, whilst the
movement of the label and timing of the electronics determines the horizontal position:
Videojet maintenance
The Videojet machines do require careful maintenance to ensure trouble free operation.
Maintenance should only be carried out by a trained technician.
Some of the more common problems are:
Shutdown procedure
The print head of the machine should only be cleaned when the machine has been
completely shut down. The reason for this is that once you press OFF on the machine
control panel, a shutdown routine is followed that returns all unused ink to the ink reservoir
and purges the ink return lines from the print head to the machine. Whilst this is happening
the LCD display will show SHUTDOWN RUNNING, and when it is complete the display
will go blank.
For this reason the machine must only be switched OFF using the red OFF button on the
front of the panel, and not by switching off the power supply switch.
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Another useful tip is to wipe Vaseline over the pallet cups, pallet shafts and safety doors of
the aggregate. Any glue then wipes off easily, but the Vaseline must not be put on parts
that touch the label, such as the pallets themselves.
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Safety
Objective
Identify safety features in a labeller
Identify good practices of operating a labeller safely.
The Labeller aggregate contains moving parts that follow a complex pattern of movement
at high speed. Many operators have attempted to remove excess labels from pallets or
glue roller and paid with the instant removal of a finger.
The aggregate is protected by screens, and
these must be kept closed during operation of
the labeller.
Safety sensors are built in to stop the
machinery if the screen is opened. Do not
bypass the sensors. Only ever use a plastic
scraper to remove excess labels:
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Labeller Questions
Question One:
Which statement is true regarding the labels used on Heineken products ?
TICK HERE
A
Question Two:
Which of the following is not a feature of good label paper ?
TICK HERE
A
Flexibility
Lead content
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Question Three:
Which of the following is NOT a function of label coding
TICK HERE
A
Religious function
Best before
Made from.....
Label manufacturer
Question Four:
Which of the following is NOT used in label manufacture?
TICK HERE
A
Cellulose fibres
Starch additives
Chalk
Resin
Question Five:
Which of the following are NOT functions of a label ?
TICK HERE
A
Identifies ingredients
Question Six:
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Which of the following materials are NOT used to make containers for carbonated
beverages?
TICK HERE
A
Plastic
Glass
Paper
Aluminium
Question Seven:
Which of these are NOT label materials ?
TICK HERE
A
Plastic
Glass
Paper
Aluminium
Question Eight:
Which of these are types of label according to their function or position ?
TICK HERE
A
Screw cap
Leg
Neck
Finger
Question Nine:
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Tuchenhagen
Alfa Laval
Sander Hansen
Vir Mauri
Question Ten:
Which of the following does the gap detector sensor NOT detect at the labeller
infeed conveyor ?
TICK HERE
A
Uncrowned bottle
Incorrect crown
Burst bottle
Fallen bottle
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Question Eleven:
Which of the following are components of the aggregate ?
TICK HERE
A
Drive motor
Brushes
Pallets
Bottle platforms
Question Twelve:
Which of the following are possible combinations of materials used in the aggregate parts ?
TICK HERE
A
Question Thirteen:
Which of the following are components of the gripper cylinder ?
TICK HERE
A
Hammer
Anvil
Thumbs
Camshaft
Question Fourteen:
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Cobb value
Curling tendency
Flexibility
Ash content
Question Fifteen:
Which of the following are paper additives ?
TICK HERE
A
Watermarks
Sizing agents
Bleaches
Metallisers
Question Sixteen:
Labels pulping in the washer can cause the following problems:
TICK HERE
A
Excessive foaming
Question Seventeen:
Which of the following are types of label glue ?
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TICK HERE
A
Glucose
Gum arabic
Colloidal
Casein
Question Eighteen:
What are the optimum storage conditions for labels:
TICK HERE
A
Question Nineteen:
Which of the following adjustments affects the skewness of the label ?
TICK HERE
A
Glue temperature
Question Twenty:
Which of the following are methods of date coding ?
TICK HERE
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Laser
Bubblejet
Inkjet
Phasor
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Answers
Question 1 B
Question 2 D
Question 3 D
Question 4 C
Question 5 B
Question 6 C
Question 7 B
Question 8 C
Question 9 D
Question 10 B
Question 11 C
Question 12 A
Question 13 B
Question 14 A
Question 15 B
Question 16 B
Question 17 D
Question 18 A
Question 19 B
Question 20 A
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Glue
Aggregate
Aluminium Foil
Anvil
Binder
Cam
Casein
Cobb value
Coherent light
Conti Roll
DC stepper motor
Flagging
Fourdrinier
Grammage
Gripper Cylinder
Halaal
Hemp
Ice Proof
Infra-red
Isolator
Jog Button
Kosher
Laser
Metal Type
Metallised label
Mimic Panel
Monochromatic
Pallet
Papyrus
Parchment, Vellum
PET
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Photon
Pictograph
Piezo-electric crystal
Pigment
Pulped labels
Radial
Scraper blade
Sizing Agent
Skew
Solenoid
Stylus
Tangential
Ultra-Violet
Vaseline
Vernier
Viscosity
Wavelength
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