Introducing label dispensing and application technology

This was all pioneered by R. Stanton Avery, who reportedly used a matchbox as a peel plate or beak. Today’s global industry is founded on these same principles.

Hand dispensers will normally be on a packing table or bench, with the product to be labeled taken to the machine for the label to be applied. With larger items the dispenser may be mobile and taken or wheeled to the product.

HAND-HELD LABELERS

From the early, relatively simple machines used to dispense and apply labels by hand, have evolved a variety of hand-held labelers – including those that can print one, two, or three lines of fixed, variable or sequential information before dispensing. Hand labelers, including those with print capabilities, need to be both robust enough to withstand continuous handling, and relatively lightweight to avoid hand and arm strain.

An example of a modern hand labeler can be seen in Figure 1.2.

Like hand dispensers, hand labelers will incorporate a label unwind spool, a stripping plate to remove the backing and feed the label forward for application, and usually, a backing liner spool to take up the waste.

Some early models used sprocket holes in the webs to allow the liner to be ratcheted forward to create the pull around the beak or peel plate. Hand labelers are designed to be portable and taken to the product.

Hand labelers, and those with simple one, two or three line print capabilities, come in a variety of designs, shapes and widths, but are limited in the length and width of labels that can be applied by the need for portability and ease of handling.

Semi-automated or fully-automated labeling machines are used to apply pressure-sensitive labels from a roll of labels onto a container or product, supplemented by the latest generations of high-speed ‘intelligent’ and rotary applicators and sophisticated labeling lines.

AUTOMATED AND ‘INTELLIGENT’ APPLICATORS

These more advanced machines may be controlled by touch-screen interfaces, microprocessors and use programable logic controllers, servo drives, sophisticated label or product sensing devices – both contact and non-contact – scanners and vision inspection systems, as well as having the potential to add a whole variety of mechanical or electronic overprinting devices into the labeling head or labeling line. 

All types of pressure-sensitive dispenser or applicator have a number of key things in common.

Firstly, a means of peeling the release liner or backing away from the label. This is usually accomplished by unwinding a reel of die-cut, or sometimes butt-cut, labels and then pulling the web under tension around a peel plate or beak. As the backing is taken around the sharp angle of the plate, the front edge of the label is ‘released’. Advances in high-speed release have been vital in developing the latest generation of high-speed applicators.

Once the label starts to be released from the backing, there are various ways of feeding it forward and pressing (applying) it to a pack, container or product.

A number of different devices – including rollers, brushes, tamp pads or air jets – are used to ensure the label sticks with a positive contact to the product or container. 

Some systems can provide a limited number of shapes cut to the top and bottom, although the laminate material is more commonly printed, without die-cutting, at full press speed and subsequently converted into a single ply linerless label on a special machine or converting operation.

In summary, if an end user needs to apply pressure-sensitive labels to almost any kind of product shape or size, in any kind of environment, whether over-printed or not, and with or without a backing release liner, there is an application system able to do the job. The technology available today is summarized in Figure 1.10. 

Some systems can provide a limited number of shapes cut to the top and bottom, although the laminate material is more commonly printed, without die-cutting, at full press speed and subsequently converted into a single ply linerless label on a special machine or converting operation.

In summary, if an end user needs to apply pressure-sensitive labels to almost any kind of product shape or size, in any kind of environment, whether over-printed or not, and with or without a backing release liner, there is an application system able to do the job. The technology available today is summarized in Figure 1.10. 

Very fragile or delicate products can be labeled using jets of air, without the physical contact of a roller or pad. Applicator systems employing pneumatics are used in flame-proof situations for labeling spirit or alcohol-filled containers.

Custom machines have been built to label beer kegs, car windows and make-up compacts, and for applying labels to internal membranes on air bag deployment tubes, bundling rods, and for wrapping tapered products.       

APPLICATION FLEXIBILITY

The direct transfer of labels from a reel permits exact placement in front, back or neck positions, on top or bottom, into recesses and around corners in any combination, depending on the number of application heads on the machine (see Figure 1.11). Changeover of labels from one design or bottle type to another takes about 15 minutes. Any combination of labels on a three-head applicator can be changed at any time, thus providing extreme flexibility.

The latest modular labeling systems allow wet-glue, pressure-sensitive, linerless, wrap-around or sleeve labeling options on one machine.