Automation Control for Pressure

Sensitive Labeling Machines

Lower Total Cost to Design, Develop and Deliver™
Solutions from Rockwell Automation

Advantages
• Extended machine lifecycle –
Advanced programming routines
that allow registration control with
different materials. Less wear and
tear on mechanical systems at any
speed with electronic camming
and registration control that
allow smooth product and label
management.
• Machine optimization – Simple to
use, smarter machines and easier
to maintain. Increased machine
flexibility to handle multiple SKUs
and different glue patterns. Ability
to handle different labeling materials
without slippage and accurately
handle registration at varying speeds.
Photo Courtesy of NJM/CLI Packaging Systems
• Jump start programming - Reduce
development time through reuse of
existing code libraries. Overview
• Reduced software packages - Labels play a large part in the life of a packaged product. The label can
One development environment for give the consumer the overall feel of the product. They can describe
discrete machine control, registration the product, how to use the product, the proper ways of disposing the
control, temperature control, motion, product, plus any warnings or potential dangers with the product. Labels
and drives programming reducing may also contain both readable and non-readable information such as
development time and cost. bar codes, RFID and holograms to slow down counterfeiting and to keep
• Reduced downtime - Less downtime track of the product throughout the packaging, palletizing and transfer of
after emergency /scheduled stopping the product to the consumer. Labeling machinery varies from hand held
with integrated safety system. individual applicators to high-speed multi-head applicators that can print
• Easy-to-use, off-the-shelf (OTS) and apply on highly automated packaging lines. Labeling is critical to the
components - Reduce time to process. If you can’t label a package you can’t identify or ship a product.
market and meet end user demands
for simplicity and global support. Labels and labeling machines come in wide variety of types. They are
generally split by either the application of adhesive which are: Pressure
Sensitive Labeling Machine, Hot Melt Glue Labeling Machine and Wet
Glue Labeling Machine.
A Pressure Sensitive Labeling Machine applies pre-glued labels that
are supplied on a reel of release paper or film. Pressure sensitive labels
undergo multiple manufacturing steps to have the label temporarily
adhere to a web or roll but will permanently adhere to the package. There
are multiple types of applicators but they all share the capability to peel
the label away from the web or backing and transfer it to a package.
After the pre-glued label is peeled from the web there
are several ways to apply the label. The simplest way is to
wipe the leading edge onto to the package. The other is
to transfer the label to an applicator drum which holds on
to the label by vacuum or other mechanical means before
transfer to the package. Typical speeds are 1200 inches
per minute but higher speeds are possible.
Pressure sensitive labelers are becoming more popular
because the user does not have to use glue, thus resulting
in a lower maintenance and lower operator intervention.
Challenges
Several challenges exist for labeling Machine Builders.
One area is in product handling and alignment—if the
machine can’t control the product being labeled, then
the label placement is inconsistent. The machine needs
to be able to cut, register, apply adhesive, align and apply
the label for the various materials used to label the
product. Lighter labeling materials can cause slippage
and registration issues.
The Machine Builder must adapt to machinery
adjustments and maintenance requirements to
different products and different label material at
shifting production speeds with varying environmental
conditions. How fast and how easy it is to do these things
is of the utmost importance to the success of the labeling
machine builder. Labeling machine builders need to
adapt to varying production speeds, frequent product
and material changeovers as well as the ability to handle
thinner or more sustainable materials. They are also in
need of more advanced techniques which can include
track and trace, print and apply technology, and post
application inspection and verification. Smarter, simpler
machines with quick roll changing techniques, more
advanced label inspection and rejection techniques
and less human involvement are important as well.
Working with Rockwell Automation you can lower your Total Cost to Design, Develop, and Deliver a machine. This
total cost approach solution accounts for all costs of delivering a machine or system to market over a given period
of time. It is a final result of the purchase and build costs plus all aspects in the future use and maintenance of the
machine components considered.
Solutions
Labeling machine builders need scalable automation
solutions to accommodate the wide range of capabilities
they want to offer end users. The Rockwell Automation
product portfolio helps develop machines with the
right amount of control, power and information, but
with the flexibility needed to make future adjustments.
The Logix Control Platform with integrated motion is
an integral part of Rockwell Automation Integrated
Architecture™, which combines networking, visualization,
and information technologies to help you lower your
Total Cost to Design, Develop, and Deliver machinery.
Unlike conventional control architectures, it provides
fully integrated, scalable solutions using a single control
platform and a single development environment.
This enables machine builders to efficiently re-use
engineering designs to help reduce development time
and cost and greatly enhance business performance.
Integrated safety solutions combine safety, motion and
discrete control capabilities throughout the controller,
drives, servos and networks. New safety technologies
like safe-speed, safe-direction and safe-off help to
significantly reduce development time, maintenance
costs and nuisance shutdowns to keep machines running
at optimum efficiency. Rockwell Automation integrated
safety solutions are focused on overall machine
performance, including safety, efficiency, and design
productivity, helping machine builders deliver flexible,
high-performance machines.
Modular Programming encompasses code structuring,
tag naming conventions, state model implementation,
HMI practices and more. It is based on industry standards,
and provides a consistent framework to get the most
from the Integrated Architecture.
Access to the off-the-shelf control components built
to industry standards for system design, start-up and
repair are critical. With more than 450 sales and support
locations in 80 countries and a network of authorized
Allen-Bradley distributors as well as our Global OEM
Technical Consultants (GOTCs) — the supply and support
of Rockwell Automation is incomparable in reach.
 Labeling Machines: Typical Architectures

Higher Performance

PanelView™ Plus HMI CompactLogix™ Controller

In Feed Kinetix® 6000 Servo Drive

Label Registration
Product Registration

Star Wheel

Ethernet Switch

Glue

Label Roll Cutter Smart Belt Smart Belt

Out Feed
Glue Control
Rejection system
Label & Production sensors

Vacuum Roll Point I/O™

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Allen-Bradley, Integrated Architecture, Total Cost to Design, Develop and Deliver, PanelView,
Micro800, PowerFlex, Kinetix, ControlLogix, Point I/O are trademarks of Rockwell Automation Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP149A-EN-P – June 2011 Copyright ©2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.