Foreword
Weiler Labeling Systems (WLS) meets the most demanding pharmaceutical labeling needs – in terms of speed, accuracy, printing, and vision systems – with its state-of-the-art rotary pressure-sensitive label applicators. When entering the pre-cut label market, WLS aimed to avoid some of the drawbacks of traditional cold-adhesive label applications. By combining its decades of rotary labeling expertise with NuLabel's innovative adhesive-free labeling technology, WLS is now able to offer cleaner, more efficient pre-cut label applicators. To meet these specific industry needs, as well as the general requirements for increased flexibility, efficiency, and easy changeover – while maintaining price competitiveness comparable to traditional solutions – WLS relies on automation technology from B&R and POWERLINK with deterministic synchronization characteristics.
WLS's pre-cut label applicator eliminates the need for glue, combining the high efficiency of pressure-sensitive labelers with the low cost of pre-cut labels.
Weiler Labeling Systems (WLS) has over 25 years of experience in designing, manufacturing, integrating, and supporting advanced pressure-sensitive labeling solutions, establishing a leading position in the pharmaceutical industry where labeling machines need to handle increasingly complex printing and vision functions for serial number coding. These state-of-the-art applications require equipment capable of printing and inspecting complex barcodes at speeds exceeding 500 sheets per minute, while maintaining positioning accuracy within +/- 0.5 mm. Solutions in this area are typically achieved using pressure-sensitive labels provided by the company's RL-420 or RL-760 rotary labeling machines.
New fields, new methods
Having honed its skills in pressure-sensitive labeling, WLS decided to expand its business into a completely new area: pre-cut labeling machines. Pre-cut labels are cost-effective and versatile, widely used in the food and beverage industry; however, this traditional application method using cold glue is messy and labor-intensive, requiring downtime for cleaning and maintenance. To add something special to its new pre-cut labeling machine, WLS partnered with NuLabel Technologies, which has developed a revolutionary activated adhesive technology. During label production, the adhesive is pre-coated onto the label and then activated by a water-based spray before labeling. Thanks to this glue-free technology, the RL-840N labeling machine not only provides customers with versatile pre-cut labels but also achieves efficiency and appearance comparable to pressure-sensitive applications.
Centralized machine control, distributed I/O and motion
Both the RL-420/760 pressure-sensitive labeling machine and the RL-840N pre-cut labeling machine are motor-intensive devices, demanding extremely high speed, accuracy, and deterministic real-time communication. To achieve this, WLS turned to B&R Automation. B&R solutions combine centralized machine control with distributed I/O and motion control, all using POWERLINK communication. This allowed WLS to use a smaller electrical enclosure than their existing PLC-driven labeling machines. The RL-840N features 12 to 24 stepper platforms on its turret, with the screw, turret, and machine pre-cut label module driven by servo motors. “B&R’s stepper motors offer similar functionality to servo motors, but in a more compact and economical way,” explains Philippe Maraval, Vice President of Sales. “This allows us to offer our customers prices comparable to traditional mechanical cam machines and flexibility comparable to servo machines.”
The RL-840N not only provides WLS customers with the flexibility to use a quick-change programmable recipe system, but also helps to achieve a smaller footprint at a higher cost-performance ratio, thanks to the cost-effectiveness of B&R stepper motors.
Achieving microsecond-level precision through POWERLINK
To match the performance of mechanical cam machines, all servo and stepper motors must achieve microsecond-level synchronization accuracy. In-line vision and printing equipment also require the same high precision. POWERLINK significantly improves cycle time, trigger accuracy, and product tracking, helping to address many challenges associated with high-speed coding and labeling. Integrating third-party devices through POWERLINK also reduces the amount of wiring required to incorporate them into the machine control system.
“POWERLINK technology enables microsecond-level communication, achieving incredible levels of synchronization. This allows motors to communicate efficiently and reliably – even through slip rings on the turret. POWERLINK has also helped us achieve the results we want in high-speed online vision inspection and printing,” said Ted Geiselman, President of WLS.
Safe and reliable
The AutomationPC910 and AutomationPanel900 multi-touch displays were selected to provide machine computing and HMI performance. This solution allows WLS to control machine functionality based on each user's login information. Users can be restricted to any combination of basic operations and advanced maintenance functions, or granted full administrator privileges. Compared to WLS's previous labeling machines, B&R's integrated safety technology not only further reduces wiring but also provides multi-machine configuration options for fully programmable safety responses. Furthermore, the modular PC and HMI integration offers exceptional flexibility for expanding processing performance and adapting to future machine upgrades.
WLS's RL-840N utilizes B&R's distributed control technology throughout the machine, including ACOPOS micro servo drives, ACOPOS micro stepper drives, and X20 and X67 I/O modules – providing a scalable and cost-effective solution.
Small footprint, superior performance
WLS labeling machines are typically integrated into packaging production lines. The RL-420/760 and RL-840N not only provide WLS customers with the flexibility to use a quick-change programmable recipe system, but also help achieve a smaller footprint at a higher cost-performance ratio, thanks to the cost-effectiveness of B&R stepper motors.
The pre-cut label module on the RL-840N labeling machine is driven by a B&R servo motor, and the adhesive pre-coated on the label is activated before labeling.
“The flexible and scalable hardware topology built on top of POWERLINK communication allows us to achieve a distributed control architecture that adapts to our machine specifications,” said Ted Geiselman, president of WLS. “This not only reduces the overall size of the electrical enclosure but also improves machine performance.”
WLS currently relies on B&R's hardware and software for its pressure-sensitive labeling machines and pre-cut rotary labeling machines. "In the future, we will continue to expand the use of B&R products in our labeling machines and other platforms," Geiselman concluded.
