We all appreciate how important labeling is in the product packaging process. Someone new to manufacturing and automatic labeling may not immediately realize how unstable containers or bottles can make this important step such a challenge. Irregular containers with rounded or uneven surfaces can cause labeling errors and inconsistencies, resulting in significant production delays, waste, and financial losses. This blog aims to provide practical tips and recommendations on optimizing your labeling process and maximizing efficiency with unstable container labeling equipment.

Puck Conveyor Labeling Systems

Rising to the Challenge of Labeling Unstable Containers

In our experience, many types of unstable containers and bottles are challenging to label. Differentiation makes us seek out totally unique packaging to entice potential new clients; however, rounded, curved, or uneven bottoms or containers with a smaller base diameter than the body have their pitfalls. Characteristics such as these tend to cause significant labeling errors and inconsistencies, leading to production delays, waste, and financial losses.

Unstable containers can also compromise product quality and safety, especially in the food, beverage, and pharmaceutical industries that are heavily regulated and require accurate labeling. As a result, there is a real need for labeling solutions that can effectively stabilize irregularly shaped or unstable containers and ensure accurate and consistent labeling outcomes. In the following sections of this blog post, we’ll explore how to address these avoidable challenges.

The Advantages of Automated Puck Conveyor Systems

Automated puck conveyor systems are handling devices widely used on filling & labeling packaging lines because unstable products cause challenges throughout the conveying & handling process. Puck Conveyor Systems are designed to grip containers firmly and lock them into a stable position as they are conveyed from one station to another. They can handle a wide variety of container shapes and sizes, from small test tubes to large jars. They prevent any wobble or tilt and ensure accurate and consistent labeling free of wrinkles or buckling that often occur from even small shifts in container positioning.  It effectively reduces the risk of production errors, injury and wastage, resulting in significant business cost savings. It also dramatically reduces the need for manual container stabilization and positioning, which is time-consuming and labor-intensive. Puck handling tools provide the versatility, efficiency, and cost-effectiveness to optimize any business’ labeling process.

Gernep Designed Puck Handling Systems

At Gernep, we pride ourselves on our innovative approach to puck handling, which sets us apart from other systems on the market. Working with customer feedback about the frustrations client had experienced with standard puck-handling systems, our engineers set out to root out the reported pitfalls.

At Gernep, we pride ourselves on our innovative approach to puck handling, which sets us apart from other systems on the market. Working with customer feedback about the frustrations client had experienced with standard puck conveyor systems, our engineers set out to root out the reported pitfalls.

With Gernep‘s puck-handling system, the container and product pass through the infeed screw and are separated using a clamping mechanism in the infeed starwheel. The product moves onto the carousel and is securely held between the container plate and centering bell, while the puck is mechanically guided underneath the container table and synchronized to meet the product when discharged. Finally, the product and puck are merged once again to continue along the production line.

The entire system was designed to address the pain points discovered from customer feed-back and also with cost-effectiveness in mind. Because a singular puck can be used for many dimensions there is no need to customize the machine’s construction or to purchase various puck sizes.

Factors to Consider When Implementing Automated Puck Conveyor Systems

Several factors need careful consideration to obtain optimal performance and efficiency when integrating automated puck systems into a production line.

Consideration #1 – The type of container to be stabilized

Different puck systems exist and are adapted to different container shapes and sizes, in some cases it is possible to have pucks custom-made.

Consideration #2 – Labeling speed and throughput requirements 

Some puck systems may be better equipped to handle high-volume labeling than others. 

Consideration #3 – The associated costs

Evaluate the cost of the system, maintenance requirements, and the level of technical support and training available from the manufacturer.

Compatibility between the puck system, labeling machinery, and other production equipment is critical. When purchasing a new labeler, OEMs typically have puck conveyor systems as options on base machinery and will be more than happy to advise on the best solution & help with integrational services. The above considerations hold much more value when purchasing a used machine that needs retrofitting or refurbishing. Either way, if you have unstable product packaging selecting a container-appropriate automated puck system will significantly improve labeling processes and help achieve accurate and efficient labeling.

Final Word

Maximizing labeling efficiency on unstable packaging in the labeling process is crucial for businesses seeking to stay competitive in today’s market. Using a puck handling system for container stabilization is a valuable tool to significantly improve labeling efficiency, accuracy, and consistency which equates to reduced labeling errors and production wastage.

Puck conveyor systems can be customized to fit the unique needs of different businesses, making them versatile and cost-effective solutions. With the right equipment and strategies in place, streamlining packaging and labeling processes will increase competitiveness, and drive growth!