Of course. Automatic labelling of bottles is a critical process in manufacturing across industries like food & beverage, pharmaceuticals, chemicals, and cosmetics. It has evolved from manual application to highly sophisticated, automated systems.
Here’s a comprehensive breakdown of automatic bottle labelling:
How Automatic Labelling Machines Work
The core process can be broken down into a few key steps, common to most systems:
- Bottle Handling & Separation: Bottles are fed into the labeller, often via a conveyor belt. A screw feeder or starwheel is used to singulate the bottles, ensuring they are spaced correctly and positioned accurately for labelling.
- Label Dispensing: The label, stored on a roll (roll-fed) or in a magazine (cut & stack), is presented for application.
· Roll-Fed: Labels on a continuous roll are moved past a peeling edge. The adhesive-backed label is peeled away from its liner and presented for application.
· Cut & Stack: Pre-cut labels are picked from a stack by a vacuum pad or a blow-applicator. - Label Application: This is the core action where the label is attached to the bottle. The main methods are:
· Wipe-On: The peeled label is held by a tamp pad or roller. As the bottle passes, the applicator wipes the label onto the container with precise pressure.
· Blow-On: A stream of compressed air is used to “shoot” the label onto the bottle from a short distance. Ideal for fragile containers or irregular shapes where physical contact is undesirable.
· Roll-On: The bottle is rolled against the label, which is presented on a drum, wrapping the label around the container. Perfect for full-body wrap-around labels. - Curing & Pressing: After application, the bottle often passes through a set of brushes, pads, or rollers that smooth out the label, remove air bubbles, and ensure the adhesive bonds fully with the bottle surface.
Key Technologies in Automatic Labelling
- Labelling Applicator Types
· Pressure-Sensitive (PS): Uses self-adhesive labels on a roll. This is the most common and versatile type, allowing for complex shapes and high-speed application.
· Glue-Based (Cold Glue/Hot Melt): Applies liquid adhesive to the label (or bottle) before application. Often used for paper labels on glass bottles (e.g., beer, wine) and is very cost-effective for high volumes.
· Sleeve Labelling: Uses a pre-formed plastic sleeve (shrink or stretch) that is applied over the top of the bottle and then conforms to its shape using heat (for shrink) or mechanical force (for stretch). Common for full-body decorative labels and multi-packs.
- Automation and Control Systems
· Programmable Logic Controllers (PLCs): The brain of the machine, controlling all movements, timings, and sequences.
· Sensors: Photoelectric sensors detect the presence and position of the bottle to trigger the labelling head with perfect timing.
· Servo Motors: Provide highly precise and dynamic control over the label feed and application, enabling quick changeovers and complex labelling patterns.
· Vision Systems: High-resolution cameras inspect the label for presence, position, alignment, and print quality after application, rejecting any faulty products.
Benefits of Automatic Labelling
· High Speed & Efficiency: Can label hundreds, even thousands, of bottles per hour, far surpassing manual capabilities.
· Consistent Accuracy & Quality: Eliminates human error, ensuring every label is applied straight, in the exact same position, and without wrinkles or bubbles.
· Reduced Labor Costs: Significantly lowers the need for manual labor on the production line.
· Enhanced Traceability: Easy integration with systems for printing and applying variable data like barcodes, QR codes, batch numbers, and expiry dates.
· Flexibility: Modern machines can be quickly reconfigured (with servo drives) to handle different bottle and label sizes, supporting mixed production runs.
· Improved Safety: Reduces repetitive strain injuries and keeps workers away from fast-moving machinery parts.
Challenges and Considerations
· High Initial Investment: Automated labelling systems can be expensive to purchase and install.
· Maintenance Requirements: Require regular cleaning, calibration, and maintenance to ensure consistent performance.
· Changeover Time: Switching between different bottle/label sizes takes time, though servo-driven systems have minimized this.
· Label Quality Dependency: The machine is only as good as the materials it uses. Poorly cut labels or inconsistent adhesive can cause jams and misapplications.
· Complex Integration: Must be seamlessly integrated into the existing production line, which can be an engineering challenge.
Emerging Trends and the Future
- Integration with Industry 4.0: Labelling machines are becoming smart, connected devices. They can provide real-time data on production rates, downtime, maintenance needs, and quality control metrics to a central system.
- Robotic Labelling: For complex, low-volume, or highly variable tasks (e.g., labelling custom gift sets), flexible 6-axis robots equipped with labelling heads are being used. They can adapt to almost any shape and orientation.
- Digital Printing Integration: “Print-and-Apply” systems allow for mass customization. Each label can be printed with unique information on-demand right before it’s applied, perfect for personalized promotions or small batches.
- Sustainability Focus: Development of linerless labels (eliminating waste backing paper), use of recyclable PET films, and water-based adhesives are gaining importance.
Key Manufacturers
Companies like Sidel, Krones, Label-Aire, Weber Packaging, and P.E. Labellers are leading players in the automatic bottle labelling market.
In summary, automatic bottle labelling is a mature but rapidly advancing field that is essential for modern, efficient, and high-quality production lines. The choice of technology depends entirely on the specific requirements for speed, container type, label material, and budget.