Ever since pressure-sensitive labelers became established in mainstream labeling applications, there has been a need to reduce or eliminate the downtime caused by label roll changes – after all, the old cut label equipment that had been used could be reloaded with labels on the fly.
When I worked in R&D in the 1990s, I was involved in a project to develop an automatic label splicing unit. This device would automatically detect the end of the running roll, accurately scut the web in the correct position and spice the start of the new roll to it, without operator intervention.
While this product worked, it never really took off, and most companies looking to reduce downtime added redundant labeling heads that could switch from one to another as an alternative.
Some companies did persist with offering automatic splicing systems, especially when using labels that had no release-liner, but there is now a new option on the market the NJM Unisplice™ 413.
“Unisplice represents a significant breakthrough in pressure-sensitive labeling, improving overall equipment effectiveness by 10 percent or more compared to manual splicing.
”Traditionally, the labeler would need to be stopped entirely during label roll changes and required an operator to be present at the exact time the previous roll ended. Now, the operator can prepare the next roll at their convenience while the previous roll is still running, since Unisplice will automatically splice without the operator present at the machine. With this improved productivity, Unisplice helps customers enhance their bottom line and can pay for itself in just a few months.”
~ Mark Laroche, Vice President of Sales for NJM
The Unisplice is designed to automatically splice the end of the used roll to the start of the new one, eliminating the need to stop the machine for label roll changes.
Control capabilities have evolved greatly since the 1980s. While my old splicing system had to make do with clutches and pneumatics, the Unisplice is servo-controlled with a modern touch-screen HMI interface.
NJM’s new splicing system can be purchased with new labeling equipment and can also be added to labelers already in the field.
You might wonder how NJM deals with the waste liner from the labels, since the machine usually has to be stopped to remove the material from the takeup reel.
Over the years, I’ve seen many ways to deal with this. At one point, we developed a cutter that chopped up the waste and put it in a bag (a similar system is often used on label die-cutting stations for handling the waste matrix material), just dumped it on the floor (very messy this option), or use a pair of takeup reels so one can be emptied while the other is running.
NJM seems to have adopted the twin take-up approach.
I’ll be interested to see this at Pack Expo. It looks like a good option for reducing labeling downtime and improving OEE (Overall Equipment Effectiveness).
The new splicing system can be seen at Pack Expo International booth S-3548. The full press release is also available here: NJM Unisplice.
