The final product of this system was a finished roll of film containing an identification label inside the roll, including all traceability and production information specific to that roll.
Traditionally, this label could be applied at the end of the process, after wrapping. However, in this project, the client required the label to be printed and applied before the roll-wrapping stage. This created a significant engineering challenge: the label had to be positioned precisely so that it would appear as the first internal layer once the film was fully wrapped.
Key Challenges
- Continuous production line (24/7 operation):
The system had to be integrated into an existing line that operated continuously. Installation space was extremely limited, and downtime had to be minimized. - Precise label positioning:
The label needed to be printed and applied in synchronization with film movement to ensure correct placement inside the final roll. - Mechanical constraints:
The available installation area required a compact and highly efficient mechanical solution.
Designed Solution
The final system included:
- Dual inverted printers mounted upside down to meet space constraints and printing orientation requirements.
- A motorized moving tray that positioned the printers next to the film only during the printing cycle.
- A label peeling mechanism to separate the adhesive label from its backing and accurately apply it onto the moving film.
- An automatic waste rewind system to collect the release liner (garbage backing paper) after label application.
- A rail-mounted maintenance system allowing the printers to slide out easily for servicing, reducing downtime and improving accessibility.
Project Impact
This project required careful coordination between mechanical design, motion control, and production constraints. The result was a compact, reliable inline labeling solution that operated seamlessly within a high-speed, continuous production environment.
