24 Sep High-Accuracy Labeling for Complex Containers
The Rotary Labeling Advantage
Labeling non-standard or complex structures like conical, ovaloid, multifaceted or multi-curve bottles, jars or containers can be tricky. Industries like pharmaceuticals, cosmetics, food, and beverages are turning to high-speed rotary labeling machines that are better equipped to handle this type of packaging. Rotary labelers achieve precision at scale – they’re the go-to choice for high-volume, complex container labeling.
The Challenge: Labeling Complex Containers
Traditional linear labeling machines struggle with complex shapes, and with good reason. Linear labelers are designed have products travel along a linear axis, it can’t adjust the position of the container or apply wipe down on all surfaces.
For complex containers, the lack of rotation on linear solutions makes it difficult to position the label on the correct part of the container’s surface. Thanks to the cams, container orientation and puck handling systems available on rotary labelers, it is possible to manipulate curved, multipaceted and unstable containers in such a way that the label can perfectly conform to their shape.
All labeling machines require wipe-down accessories like rollers or brushes to smooth the label once it is applied to the container surface. The limited axis of linear labeling solutions works well on flat surfaces or cyclindrical containers however, for irregular containers it is impossible to apply even pressure across the whole season. This mosly leads to adherence issues, like skewed labels, bubbling, wrinkling and a whole host of frustrating issues.
By addressing these limitations in container orientation, manipulation, and the wipe-down process, rotary labeling machines provide far better results for complex containers than linear systems.
Advanced Features for High-Accuracy Labeling
Rotary Labeling machines come equipped with cutting-edge features that ensure consistent, high accuracy labeling across various container types. These machines are capable of applying multiple labels – such as front, back, and neck labels-simultaneously, which is particularly interesting for complex containers that have original branding. Precision is achieved by using high-precision servo-motors which control the exact positioning and minimal variability even at speeds reaching 50 000 bph. Aditionally, non-stop labeling options allow continuous labeling without downtime, significantly boosting production time.
Bottle Plate
Control System
Container Orientation
Mechanical or Servo Systems
Non-Stop
Continuous Labeling
Complex Containers Across Various Industries
Rotary labelers excel in handling complex container shapes commonly found in the following industries:
- Cosmetics & Personal Care
- Berverage Industry
- Pharmaceuticals and Healthcare
- Household and Cleaning Products
- Luxury goods and Speciality Foods
They benefit significantly from rotary labelers due to their ability to handle complex shapes with precision. Rotary labelers’ rotating platforms ensure accurate label placement on curved and non-standard surfaces, while their non-stop operation and camera-based orientation systems maintain high speeds without sacrificing quality. These features allow for simultaneous application of multiple labels, enhancing efficiency and maintaining brand integrity across diverse packaging types, which is especially crucial in markets where presentation is key!
Most Common Issues – Labeling Irregularly Shaped Containers
Labeling irregularly shaped containers presents several challenges due to their non-uniform surfaces and unique designs. Some of the most common problems include:
- Label Misalignment: Irregular shapes like ovals or cones can lead to misalignment, where the label doesn’t sit properly on the container. This occurs because the label applicator struggles to adapt to the uneven surface, causing the label to skew or wrinkle.
- Poor Adhesion: Containers with curves or textures often cause the label to peel or lift off after application. This happens when there is insufficient surface contact between the label and the container, especially on containers with sharp curves or angled surfaces
- Air Bubbles and Wrinkles: When labeling curved or contoured surfaces, air bubbles or wrinkles can form under the label. These imperfections can reduce the aesthetic quality of the product and cause the label to wear off more easily
- Inconsistent Label Placement: On irregular containers, ensuring consistent label placement is difficult. Linear labelers, in particular, may struggle with orientation, leading to labels being applied at different angles on each container
- Complex Wipe-Down Process: After the label is applied, many machines use brushes or rollers to ensure the label adheres smoothly. However, on irregularly shaped
containers, these wipe-down processes often fail to apply even pressure, leading to incomplete adhesion and aesthetic issues
Mitigate these challenges with rotary labelers, which allow for greater flexibility in handling non-standard container shapes.
Key Considerations to Choose a Labeler for Your Irregular Containers
When selecting a labeler to best adress your labeling needs, you have much to gain from understanding the long-term benefits. Rotary labelers offer an attractive return on investment (ROI) because it reduces downtime and minimizes errors which lead to label waste – both of these considerations positively affects overal production efficiency!
Rotary labelers are also customizable, with the ability to incorporate on or multiple like Hot Melt, Cold Glue and Pressure Sensitive label applicators, providing extreme flexibility to manufacturers everywhere. This provides the ability to adress variances in labeling for different product lines and different shapes – not to mention the non-stop operation which means fewer interruptions and less maintenance- making them a durable and reliable solution for high-volume production environments.
Other nice-to-haves are the ability to integrate seamlessly with pre-existing machinery and equipment further enhances production flow, while modern sustainability features—like supporting eco-friendly label materials—align with growing demands for greener operations. For manufacturers focused on optimizing both performance and sustainability, rotary labelers present a compelling choice.
An Unmatched Solution for Irregular Containers
Rotary labelers are an unmatched solution for industries dealing with irregularly shaped containers. Combining high precision, flexibility, and speed, they are invaluable for businesses looking to optimize their production lines while ensuring consistency and accuracy. Their advanced features, such as non-stop operation, multiple labeling capabilities, and seamless integration with existing systems, help increase throughput while reducing maintenance-related downtime.
Furthermore, rotary labelers meet stringent industry regulations, making them ideal for sectors like pharmaceuticals, cosmetics, and food and beverages. As sustainability becomes increasingly important, the ability to use eco-friendly materials further enhances their appeal. For businesses seeking a reliable, versatile, and future-proof labeling solution, rotary labelers are a compelling choice that can enhance both operational efficiency and product presentation.
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