Pharmaceutical company upgrades labeling system

A large pharmaceutical company has newly installed and upgraded 70 sets of corrugated carton labeling systems at seven manufacturing plants.

In 2000, MPC, a large pharmaceutical manufacturing company located in the Midwestern United States, launched a labeling standardization project at its seven manufacturing plants. Since then, the company has successfully installed and accepted 70 new or retrofitted labeling systems to print and paste barcode labels for corrugated cardboard shipping containers.

The heat transfer labelling machine used in this project was supplied by Labeling Systems, a single-headed or double-headed device that can paste one or two labels for each box at a speed of 10 to 30 labels per minute. When the labeler is running, it is connected to Ethernet and downloads the barcode format from the network. The system is integrated into the existing production line and can scan and confirm up to 3 tags at the same time. Most of the systems use three computer software programs to connect with scanners, PLCs, computer screens, and reject inspection machines to retrieve tag formats and print tags.

MPC chose thermal transfer technology because it differs from ink jet or laser printing in that it can always print in multiple lines with a single print head and meets ANSI bar code and alphanumeric print quality Class A quality standard. The use of thermal transfer can increase the readout rate of the company's electronic inspection system, thereby reducing rework downtime due to product labeling errors and improving the user's one-time scan rate, resulting in the cost of MPCs, distributors and users. The reduction.

In order to select the best labeling machine supplier, MPC conducted a formal comparison of equipment operations among the six world-leading labeler companies. The main reasons why MPC chose Labeling Systems (LSI) as a supplier are:

* Labeling Systems and its distributor, NuQuest Print Solutions, can better display their products and enable customers to thoroughly understand the mechanical and electronic principles of their printing and labeling machines. This is a key part of high-level customer support services.
* The labeling machine has the smallest base surface, adopts high-quality and high-strength anodized aluminum welding structure pipes, and has print head installation and adjustment lock;
* Labeling Systems chooses MPC-approved high quality standard series of pneumatic, electronic and mechanical components;
* The system takes the shortest time to replace the label roll and the label tape, and requires the least number of idlers and drive rolls;
* All pneumatic and electronic components are easily accessible for easy replacement and maintenance.
* In the face of the challenges brought about by space constraints, Labeling Systems' equipment design solutions demonstrate the best on-site flexibility and creativity;
* Strongest in tested labellers, the largest range of labels can be processed (333 inches to 3.5313 inches)
* Labeling Systems ranks fourth in the number of sales of labellers in the United States;
* Labeling Systems is able to provide factory-site services for equipment outside the United States. This is critical in this case because some of the factories that will install such systems are located outside the United States.

Device complies with FDA regulations

Steve Sylvander, the equipment manager for NuQuest Print Solutions, recommended Labelling Systems to MPC because of the superior quality of the electronics and mechanical components used in the labeler. This is the case for the high-capacity vacuum fan that sucks the label on the labeler. It is more reliable and more cost-efficient than the Venturi vacuum device. PLC manufacturers working with Labeling Systems provide communication devices that represent the state of the art, such as DeviceNet, Profibus, Net ENI modules, and small human-machine interfaces. Sylvander said: "With the help of the standard series of components, Labeling Systems' customers can upgrade the system by adding linear 2D laser and RFID scanners, vision systems, and reject rejects to the human-machine interface and the computer. PLC can also be connected to existing warehouse management software or ERP software to provide real-time inventory of inventory and product tracking data.

A blank white pressure-sensitive label was peeled from the paper liner, placed on a pressure pad, and held in place by vacuum suction. When the carton passes through the sensor, the sensor activates the labeler and stretches the label onto the carton when the carton passes through the conveyor belt.

Sylvander also mentioned that MPC needs to comply with FDA regulations, such as the 21 CFR (Part 21 Federal Regulation Act), Part XI, which requires clear electronic batch records. NuQuest conducts factory acceptance inspections at Labeling Systems, and conducts verifications at MPC's facility to ensure that the labeling system and all software packages involved meet the requirements of 100%. Sylvander said: "Most of the large pharmaceutical companies have their own internal standards, we will incorporate these standards into the design data, to carry out follow-up inspections throughout the project process."

Unified function Design flexible

NuQuest Corporation is a system integrator and participates in the development of Visual Basic software, equipment installation, and factory acceptance. NuQuest works closely with dedicated support staff for information systems at various factories and has also established partnerships with MPC. In conjunction with the three-shift production schedule, NuQuest's seven major MPC plants use off hours to provide maintenance and training services. The efforts made in training have achieved good results. The print head is the most expensive but also the most wearable component of the entire printing machine. It is carefully maintained in the factory, which proves the effectiveness of the training. Recent reports from various factories have shown that the life of the print head exceeds 7 to 9 times the warranty period.

The computer of the labeling system is connected to the server and can retrieve and automatically download the label format according to the work instruction input by the operator.

The labeling systems of the seven factories are very similar. In response to the different requirements of each factory, Labeling Systems and NuQuest must demonstrate flexibility and creativity. The two companies offer different options in the design. For example, the factory can use Sato printing machinery or Zebra printing machinery. They can choose Rockwell/Allen-Bradley PLC or Siemens PLC. Common components include rotary or rectilinear labeling devices, transfer devices, operator interfaces, computer monitors and keyboards, and shift registers for tracking and culling. The computer is connected to a server to automatically download the label format. The operator retrieves the label format by entering the work instruction through the label search software. The software operation requires both a password and an electronic tag. As a further check, a second operator is required to provide a tag scan to confirm that the input work order is correct. The format is then printed out using Easylabel print software provided by Tharo Systems.

Labeling Systems' systems use Pentium III or higher computers and copy the label copy format from the MPC work order to the printing machine through Easylabel software. A MicroLogix 1500 PLC manufactured by an Allen-Bradley company monitors input and output and communication of upstream and downstream equipment. The system is equipped with Datalogic's fixed bar code rasterizer, which scans the bar code on each tag and compares it with the operator's input work instruction standard. There is also the Banner SM312LV retracing optical eye, which tracks the passage of the carton through the entire system.

The computer's authentication software and computer digital input/output card connect the barcode scanner, slot reader, display, and PLC together. The PLC controls the label affixer, bar code scanner, print head, reject device, transfer device, and computer display.

Die-cut labels are provided by NuQuest and are distributed on a peelable pharmaceutical grade label roll at 1/8 inch intervals. The label on the roll is pulled into the print head by the printer's stepper motor and the print head can print up to three 10 mil (1/1000 inch) UCC/EAN 128 linear barcodes on each label. These three barcodes are designated as basic barcodes, secondary barcodes, and quantity barcodes, respectively. The system can also print information that can be read on the label.

When the operation starts, the carton is first sent to the conveyor and sent to the labeling station. The blank white pressure-sensitive label is automatically peeled from the paper liner, placed on the pressure pad, and the label is held in place by the vacuum created by the blower. The unwind roll has a spring-loaded tension/brake arm that provides constant unwinding tension, maintains print text alignment, and minimizes the stepper motor inertial load on the print mechanism. After the label is removed, the liner is rolled onto a powered rewind drum that is coupled to a mechanical slip clutch. The carton uses a sensor to activate the labeling device. When the carton passes through the conveyor, the label is stretched and compacted onto the carton. The design of the actuator varies according to different applications such as linear, rotary, or rotary.

After labeling, the Datalogic scanner installed on the labeling head scans the basic bar code, sub bar code, and quantity bar code on the label and compares it with the bar code required by the work order. The BC verification software determines whether the barcode is readable and matchable. Cartons with unreadable, unmatched barcodes are discarded from the moving conveyor. The reject/verification photoelectric eye confirms that the tray has been pushed from the cylinder into the reject zone and passed smoothly. Scanned cartons will continue to be delivered to the stacker.