Digital technology targets coding advances: whether ink jet or laser — networking and line integration are keys to coding success - Cover Story - New printing equipment for packaging operations

Food & Drug Packaging, Dec, 2001 by Christopher Barry

The impact of the digital world is extending to one of the most common place packaging operations--coding.

The benefits of embracing digital technology into coding operations include:

* Flexibility and easier changeover. With the use of laptop computers and personal digital assistants (PDAs), easier changeover on codes becomes more secure and flexible. Package codes can now be changed with a simple and quick download from a centralized database to the printer.

* Cleaner codes. Clean codes are easier for the human eye and vision systems to read and understand. Also, with cleaner codes, product identification and tracking errors can be reduced.

With a wide array of ink jet and laser coding equipment available to packagers, here are developments that contribute to more successful coding applications:

* By integrating your coding equipment with your total packaging line operations via a personal computer (PC) or programmable logic controller (PLC), a networked system allows uninterrupted operations and faster throughput.

* Coding methods should match packaging substrates. For instance, will using ink coding be right on glass applications where moisture may interfere with the coding process? What about laser coding applications?

* Code legibility is key. With current technological advances in coding equipment, there are fewer excuses for smeared or smudged ink codes.

INTEGRATION CUTS ERRORS

In a digital age, it's how every piece of packaging line equipment is integrated--and your coding system is an integral element of the larger picture. Your whole line has to be considered if you want error-free coding operations.

Your operations can be simplified by using a centralized PC- or- PLC-based network and user-friendly software. Digital technology gives plant managers and operators more flexibility to monitor code set-up and equipment maintenance.

For example, Marconi's Integrated Solutions system provides coding equipment compatibility with other equipment and applications on the packaging line.

The goal isn't to just integrate your coding system but to streamline your whole packaging line, which adds to overall efficiency. And data capture is key.

Acquired data can be analyzed and transformed into information that can help make improvements in your packaging line. Not only does the Integrated Solutions system process data, it puts it into a database where it can be captured for future applications.

The system also helps integrate your coding equipment with other packaging line equipment like check-weighers, scales, vision systems and palletizing devices.

Software can also be used to monitor and diagnose all networked equipment in order to identify equipment maintenance needs.

Another example of digital integration can be found in Fox Jet's Auto Maintenance System (AMS), which gives operators a "hands-off" automated approach to coder printhead maintenance.

AMS reduces personnel interaction, reducing the need to manually prime printheads, which can lead to ink-clogged nozzles if done incorrectly. AMS is programmed to self-prime each printhead using plant time schedules.

With automated maintenance scheduling, more control over the actual coding operations is possible. Data can be quickly transferred, traced and accounted for saving time and labor.

But, running coding operations can be even more flexible and, in some cases, can go beyond PC-based networking.

Being able to handle coding data and printer equipment remotely can improve efficiencies while emphasizing security.

For ease-of-use, plant supervisors and managers needing to edit and input codes securely into printers can do so by using personal digital assistants (PDAs) from anywhere in the plant.

Software used with a PDA can include a menu of coders, text editing and printer identification including model, serial numbers and versions. Information can be extracted from the PDA to a printer via a serial cable or infrared sensor.

PDA software such as Markem's SmartLase PDA Interface allows users to program and operate the SmartLase laser coder with the touch of a stylus via a connection to the coder.

Portable control terminals with software can also be used to make coding changes from the production floor or anywhere in the plant.

Advanced terminals like Weber's LegiLink have keypads and liquid crystal display (LCD) readouts with simple user interfaces. Many weigh less than one pound and can reduce the need for separate printer controllers, because information can be fed into the portable terminal and downloaded into a range of printers.

SYSTEM OVERHAUL?

In some cases, coding applications may require a coding system overhaul such as replacing outdated print-pad systems with new ink jet technologies or replacing ink jet systems with laser. And that doesn't mean redoing your whole packaging line.

For instance, Marconi's Special Application Requirement (SAR) group is often called to help customers integrate and customize newer and more efficient coding applications into their lines.

Special applications engineers are used to incorporate the coding system into a packager's already existing line.