Choosing a Print-Apply System

by Dick Olhava
Manager, Labeling Systems
Weber Marking Systems, Inc.

Print/apply systems— systems that simultaneously print and apply pressure-sensitive labels— were first introduced to the industrial marketplace about ten years ago in an attempt to improve the efficiency of product shipping and identification. But it wasn’t until recently that these high-performance labeling aids have become more visible in manufacturing environments. The rise in use of bar code labeling and, more specifically, the growth of compliance labeling, have been key factors in the expansion of print/apply.

With the increase in popularity of print/apply, industry has seen many improvements to these systems. For instance, the printer components in most printer/applicator models are smaller and less expensive, providing manufacturers with more compact, more economical systems for in-line operations. The printers are also smarter, as most are driven by microprocessors that are faster than ever.

Generally, today’s printer/applicators are more flexible overall. Some models can handle numerous short runs and label a wide assortment of products that randomly come down a conveyor line. With their keen sensors, printer/applicators can automatically adjust their operation to different shapes and sizes of products. Also, bar code verifiers and various warning sensors can be incorporated into the systems so they no longer have to be continuously monitored.

In addition to helping simplify their bar code and compliance labeling, manufacturers are discovering many other benefits of print/apply systems. Especially useful to manufacturers of diverse product lines, these systems cut the expense of preprinted labels, reduce down-time, and virtually eliminate preprinted label inventory. Because variable information can be changed on demand, random labeling and product changeovers can occur quickly and efficiently.

By automatically printing and applying labels in a single operation, the cost of labor is also reduced. And labels can be applied in any number of orientations, including the top, side, or bottom of products. Many models even boast a consistent label placement accuracy of +/- 0.03 inch. With all the economic and operational benefits, a system normally pays for itself within a year.

Print/apply systems use the latest in thermal/thermal-transfer printing technology and, therefore, offer a great amount of flexibility when it comes to operational environments and software considerations. Though print/apply systems are most often PC-based, they operate with PLC and midrange platforms as well. Labeling software can be obtained for each operational environment.

The user-friendly software packages available for print/apply systems further simplify the labeling task. Large amounts of data can be quickly processed and manipulated into numerous different label formats that can include text, bar codes, and graphic images. Users can write their own labeling software or purchase “canned” packages compatible with their thermal/thermal-transfer printers. Many suppliers of printer/applicator systems will provide exclusive software and customize it to their customers’ specifications.

Types of Systems
Not all applications demand print/apply systems. In some cases, preprinted labels combined with a standard, pressure-sensitive label applicator might be the most efficient method. If, however, an application involves multiple products with small lot sizes, real-time labeling, or random labeling, a print/apply system may be just what you’re looking for.

There are basically two types of print/apply systems—next-out and loose-loop (though advancements in technology have created variations of both). Knowing your particular application needs will be crucial in determining the type of system you require.

Next-out labeling, also known as one-to-one labeling, requires a printer/applicator, an independent machine that fully integrates a thermal/thermal-transfer printer and pressure-sensitive label applicator. It is an ideal labeling system for applications with several small lots or requiring up-to-the-minute identification of random products. Printer-applicators give users the flexibility to change labels often and with extremely short notice.

They also are ideal for precise, real-time labeling because labels are printed and applied simultaneously.

With the one-to-one ratio of next-out labeling, the total application speed is limited, yet still impressive. For instance, certain models can print two-inch labels at a rate of 60 per minute. The configuration of a printer/applicator restricts users to the capabilities of the model’s printer. That, in turn, restricts the size of the label material and the rate of application.

Some manufacturers may also have to comply with specific label placement requirements. For example, regulations in the automotive industry demand two-sided labeling. The food industry also uses this method for labeling pallet loads of products. Manufacturers can satisfy this requirement with a specialized printer/applicator. Wraparound printer/applicators are next-out labeling models that print long labels and apply them around corners of products, covering two panels on a product.

Loose-loop labeling has proven to be an extremely flexible print/apply method because it incorporates a stand-alone label printer and a standard, pressure-sensitive label applicator. This application offers a wider variety in printers, naturally giving the user a greater choice in label sizes, print speeds, and application speeds. A larger selection of type fonts is also available. Labels are printed on a stand-alone printer and threaded onto an interfacing label applicator. Because the speed of the applicator is not entirely dependent on the speed of the printer, the loose-loop method typically has a faster application rate. Printers can reach up to 8 inches per second while adjacent applicators can apply labels at rates up to 180 per minute. Loose-loop print/apply systems are ideal for labeling larger product lots.

Methods of Application
Because compliance labeling demands continue to grow and applications are becoming more specialized, print/apply systems are being designed to fit even the most unique needs. Custom applicators exist for both contact and non-contact applications, for both smooth and irregular surfaces, for both extremely long labels and very small labels, and any combination thereof.

Following are some examples of application techniques for print/apply systems: tamp-pad applicators apply a pressure-sensitive label by lightly hitting, or “tamping,” a product as it passes; tamp-blow applicators eliminate contact by blowing a label onto a product from approximately one-quarter of an inch away; air-blow applicators also apply labels without contact, but from further distances; wraparound applicators employ a vacuum-drum that follows the contours of a product; and wipe-on applicators apply longer labels by gently wiping over the label with a soft brush.

Though your print/apply options seem endless, they are not. Your application will, for the most part, determine your print/apply system as well as your application technique. (Most print/apply equipment is made of corrosion-resistant stainless steel, which is virtually maintenance-free and makes it sturdy enough for all types of manufacturing environments.) Contact labeling specialists in the industry who will be able to help you analyze your application and find the most cost-efficient system for your operation.

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