As I mentioned last week, inspection is becoming a main priority for label manufacturers and there are a variety of ways to do that.
Jeff Hausen, our QA manager, explained that to me the need to expand inspection capabilities.
“Historically, manual inspection methods and sampling plans have been effective in supplying quality products to meet our customers’ needs,” said Jeff. “Customer expectations, however, are changing and are becoming more demanding, whether to accommodate streamlined production processes or increased regulations.”
This means more labeling printing jobs require extra inspection, specifically, 100 percent inspection.
We’re excited to announce that we’ve expanded our inspection equipment to include six computerized inspection units, which gives us increased capabilities for 100 percent inspection.
How They Work
AVT's Helio II
With a computerized vision system on press, an operator will be able to detect any label defect immediately – and know exactly how many labels were affected. This also will increase productivity because we’ll be able to catch the defects before the rewind process and eliminate a second press set-up process to replace defective labels.
And by identifying and fixing any problems as they occur, we will be able to reduce both scrap and cost. This makes it a green manufacturing solution that we’re excited to use!
Our New Addition
Our manufacturing department chose the PrintVision/Helios II 100 percent video inspection systems from Advanced Vision Technology (AVT) after seeing them at the 2010 Label Expo. These units will be installed here in our Arlington Heights (IL) plant on four flexo label presses and two finishing machines.
These new vision systems will be another assurance that we’ll be able to provide our customers with the label quality they expect.
“The AVT systems will provide 100 percent inspection at line speeds, a level that simply cannot be achieved with traditional manual methods or sampling plans,” Jeff added. “In addition, Weber and our customers will ultimately benefit from higher productivity and reduced waste.”
The first two units will be installed soon, and the other four will follow over the summer. We’ll be sure to post pictures and video of the units after they’re set up.
May 12
10
Label Inspection
By Margaret O’Leary
When it comes to working with pharmaceutical, food and medical labels, there is no room for error. These customers need to meet government regulations set by the FDA that ensure that the product they put on the shelves is clearly marked with health and safety information.
Our customers need to be able to meet ever-changing FDA regulations, international market regulations and meet the demands of their customers. Knowing this, Weber has made improved inspection quality a major priority.
Why is inspection important?
Our goal is to always produce the best product for our customer. The first step for this is always the quoting and proof process. Once we have a proof from the customer, we must make sure that the product we send them matches the specs requested on the proof. Making sure the material is right for the application, the barcodes are all readable and text is clear, is all a part of the inspection proof and inspection process.
While there’s no way to completely eliminate press errors, we can work with equipment to detect the errors and make sure they’re not sent to the customer. The inspection process is crucial for ensuring a quality product for the customer.
Defective labels become manufacturing waste as seen above.
Label defects can include:
- Smudges of the text
- Missing numbers or text
- Filled in print
- Incorrect colors
- Non-scannable barcodes
- Off registration
- And more!
What is 100% inspection?
- One of the 100% inspection methods — high-speed strobe.
If the job requires 100% inspection, each label is inspected for print quality.
One way of inspecting for defects is with the human eye. As the labels move along the press a strobe light is used to flash the label. This tricks the eye into seeing the label as a frozen image rather than speeding by! However, there are possible human errors so it is not ideal for medical labels.
This method still works well for many types of labels so manufacturers are finding it useful to keep a variety of inspection methods.
Next week we’ll have a blog about new computerized inspection equipment.
Posted in Labels Uncategorized by .
Apr 12
26
Happy Earth Day!
By Margaret O’Leary
Weber Packaging Solutions has made big moves towards sustainability in the last year.
Our first step was to reduce the use of disposable water bottles by our employees. Our old water fountains were replaced with three purification water coolers from Ambius Hydrofresh.
Fuel pellets made from Weber's recycled paper waste.
This has not only encouraged our employees to use reusable water bottles, but it’s also promoted drinking lots of water for a healthier diet. A great collaboration by Weber’s Green Team and Wellness Committee!
Our biggest step was reducing our office and label manufacturing waste. You might have seen our announcement in Packaging Digest! We compact the label and office waste and ship the material to Pellet America in Wisconsin where they turn it into pellets for fuel. As we mentioned Packaging Digest, this affects 99% of our waste!
These changes came from our Green Team! In addition to looking for green manufacturing solutions, the Green Team promotes Reduce Reuse Recycle to our employees. Reduce the amount of paper you print, reuse what paper you can as scratch paper and recycle it when it’s no longer usable.
In honor of Earth Day here are some green tips for at home and at the office!
- REDUCE REUSE RECYCLE – “Do I need to use this, can I reuse it afterwards and can it be recycled”
- Pay your bills online – Managing your bills online reduces the paper for the checks and the bills in the mail! You might even be able to manage all of your bills from your bank’s website!
- Use reusable grocery bags – Less than 3% of plastic grocery bags are recycled! Reusable bags last longer than plastic ones even if the plastic bag is reused. It also holds more groceries so you will probably find you have less bags to carry in the house!
- Unplug electronics that aren’t in use – Even if your cellphone isn’t plugged into the charger, it’s still taking up energy. This will save energy and save you money!
- Use less printouts – If It’s not necessary to print, keep it in a file on your computer. Printing less paper saves trees and reduces clutter!
- Set your computer to automatically go to sleep during breaks to cut energy – According to the Sierra Club, this can cut energy use by 70%
- Use the recycling bins at your desk for all paper waste
- Reduce the amount of lunch waste by using a reusable lunch box and containers for the food
- Visit a local Farmers’ Market – A farmers’ market is a great addition to your regular grocery store trips. This food travels a short distance, is in season and can be fresher!
- Use a reusable mug when you pick up coffee on your way to work - Not only is this reducing waste but some coffee shops will give you a discount for using one!
Do you have any tips to add to this list?
Posted in Green Initiatives Uncategorized by .
Looking to design a label? Looking to select the right labeling equipment? Maybe just looking to learn the latest about labeling?
Well, here’s a terrific source. It’s the Labeling Playbook, a 70-page PDF packed with information that provides end-users with a roadmap of how to be successful with virtually any type of labeling project. The content is very objective, written by Packaging World magazine’s editorial staff in consultation with leading labeling experts and end-user companies.
According to PW, “We picked the brains of leading packaging and labeling experts to compile this must-have e-book jam-packed with strategies for success, best practices, and pitfalls to avoid.” Here’s what’s included:
- Label design strategies
- Label development guidelines
- Labeling machinery trends
So, enjoy this terrific source of labeling information – courtesy of us here at Weber Packaging Solutions.
Weber's Model 4300 Pro-Apply Label Printer-Applicator
We just posted a brand new video on our Model 4300 Pro-Apply label printer-applicator. Here are some highlights of what you’ll learn:
- LCD interface provides operational status
- Numerous inputs/outputs are standard
- Wide selection of print engines
- Prints at up to 16 ips
- Select stroke lengths from 2” to 12”
- Tamp-blow label application at ±0.03
- Perfect for products and cases
And there’s more, including the fact that the Model 4300 Pro-Apply boasts an economical price tag. Take a look at the video on our website or YouTube Channel. We think you’ll be impressed by what you see.
Posted in Labeling Systems by .
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