What are the requirements for process parameters in ultra-high-speed labeling scenarios?
The first article: Die-cutting column|The control logic and practical path of die-cutting equipment accuracy in high-speed scenarios
Part 2: Die Cutting Column|How to control the accuracy of die-cutting tools in high-speed scenarios? Please master these points!
Part 3: Die-cutting column|What is the relationship between the characteristics of self-adhesive materials and die-cutting accuracy in high-speed scenarios?
In the first three articles, the author expounds the control logic and specific practice methods of die-cutting accuracy in high-speed scenarios from three perspectives: the performance of die-cutting equipment, the characteristics of die-cutting tools and self-adhesive materials, which brings great inspiration to readers. In this article, let's take a look at the specific requirements for the process in the ultra-high-speed labeling scenario?
Ultra-high-speed labeling (≥300 bottles/min) puts forward "practical" requirements for die-cutting quality, because the subtle defects of die-cutting accuracy will be infinitely magnified during the high-speed labeling process, resulting in labeling deviation, bottom paper breakage and other problems. Therefore, the die-cutting process needs to adapt to the tension, speed and positioning requirements of the labeling process in advance to form a collaborative optimization of "die-cutting-labeling".
Author: Zhang Jufeng
Adaptability of label edge accuracy
For high-speed labeling, labels need to be quickly transferred by a sharp marking plate, vacuum nozzle or mechanical jaw, and if there are burrs (≥0.05mm) or burrs on the die-cut edges, it may cause nozzle air leakage (30% reduction in vacuum adsorption) or label positioning offset.
Therefore, the error value of the flatness of the label edge after die-cutting should be controlled at ≤0.03mm, and there is no "wire drawing" phenomenon (filament caused by the adhesive layer not being cut).
After tracking the service of a beverage company, the author found that after the company controlled the label edge burr within 0.02mm, the positioning deviation of high-speed labeling was reduced from ±0.5mm to ±0.2mm, and the pass rate was increased to 99.5%, which greatly improved the yield rate of the enterprise.
Dynamic adaptation of the strength of the backing paper
The traction tension of the ultra-high-speed labeling machine usually reaches 1.5~2N, and the tension fluctuation frequency is high (about 10Hz), which requires the die-cut bottom paper to have sufficient fatigue resistance. The retention rate of the lateral tensile strength of the die-cut 35μm glassine base paper should be controlled at more than 90% (2.5N/15mm when not die-cut), and the number of bending times should be ≥ 50 times (180° folded in half) to avoid repeated bending and breakage at the turning roller of the labeling machine.
Practice has proved that by controlling the die-cutting pressure (180~220psi) and cutting depth (backer indentation ≤1μm), the strength of the backing paper can be effectively preserved, and the breakage rate of the label can be reduced from 25% to less than 2% when passing through the sharp starting plate.
Consistency of die-cut spacing
The die-cutting spacing between labels (i.e., the width of the waste discharge edge) should be maintained at a consistency of ±0.05mm, otherwise the waste discharge belt may break or the label may be torn by mistake during high-speed waste discharge. For continuous labels, the cumulative error of die-cutting spacing needs to be controlled at ≤0.1mm/10m, which requires that the feeding accuracy of the die-cutting equipment and the circumferential positioning accuracy of the tool must be highly matched.
The author once encountered a pharmaceutical label manufacturer by optimizing the synchronization of the feeding servo and tool of the production line, controlling the spacing error to ±0.03mm, and increasing the waste disposal efficiency to 99.8%.
From the content shared in the above four articles, we can conclude that the speed and accuracy of self-adhesive label die-cutting are the result of the synergy between equipment, tools, materials and downstream processes. Under the trend of high-speed and refinement, it is necessary to build a full-process accuracy guarantee system through the improvement of equipment dynamic stability, precise design of tool edges, consistent control of material characteristics, and early adaptation to ultra-high-speed labeling requirements.
In the future, with the application of intelligent sensing (such as real-time depth of cutting monitoring) and adaptive control technology, the die-cutting process will achieve the ideal balance of "speed improvement without sacrificing accuracy, accuracy guarantee without restricting efficiency", and provide core support for the high-quality development of the label industry.