GB2467516A

GB2467516A - Faulty Label Sorting

Info

Publication number: GB2467516A
Application number: GB0901347A
Authority: GB
Inventors: Kevin Triggs
Original assignee: NEWMAN LABELLING SYSTEMS Ltd
Current assignee: NEWMAN LABELLING SYSTEMS Ltd
Priority date: 2009-01-28
Filing date: 2009-01-28
Publication date: 2010-08-04
Also published as: GB0901347D0

Abstract

A faulty label sorting system, normally as part of an automated item label apparatus, features a label fault detection means, and a means 4 which displaces a faulty label from its first carrier web 5 directly onto a second web (12, fig.4). Also disclosed is a corresponding method of usage. The transfer onto the second web may allow storage of, and later reconciliation of, the faulty labels.

Description

I

Faulty Label Removal System and Method The invention relates to labelling machines in which labels are continuously or intermittently transferred from a web to articles, and relates in particular to labelling machines in which labels are checked and, if necessary, redirected so that unwanted i.e. incorrect or defective labels are not applied to articles.

Generally, labelling machines apply labels to articles such as bottles, vials, ampules syringes or other packages which have already been sealed with their contents inside. The labels precisely describe the product contained within the bottles, vials or other packages, giving basic information about the product such as the product composition, packaging date and expiry date, etc. It is particularly important in many industries, and especially in the pharmaceutical industry, that incorrect or defective labels are not applied to the articles in question. Defective labels include miscoded labels, misprinted or otherwise defective labels. Any such defective labels applied to articles may result in the product being scrapped or may potentially result in confusion and/or harm if undetected by a consumer.

In the application of labels onto containers by pharmaceutical labelling systems it may be necessary to identify and remove faulty labels from the process. These faulty labels are typically identified by opto-electronic means, applied to a container, tracked through the labelling system and subsequently automatically rejected from the packaging line.

In the food and pharmaceutical industries in particular, high levels of accuracy and reliability in the labelling process is required. Therefore, systems have been developed which detect incorrect labels both prior to and following application of the label to the article. It is preferred that the defective labels are detected prior to application of the label to the article..

Once a defective label has been identified, it should preferably be removed or redirected from the flow of labels so that it is not applied to an article.

As can be seen below, either the faulty labels are removed from the original web using complicated methods such as compressed air or vacuum drums, or are retained on the original web instead of being applied to the article at the label application stage.

The following faulty label removal system uses compressed air to remove the faulty label from the web of labels.

US-6450227 (Labardi) describes a label check station for auto-adhesive labels in a labelling machine. The label check station co-operates with a control unit which co-operates with a working groupfor removing defective labels from a label carrier band. The labels are removed from the label carrier band by moving a plate in contact with the label carrier band when a defective label is found. The plate lifts the edge of the label from the label carrier band and then compressed air is directed at the edge of the label to blow the label from the label carrier band, on to a cardboard core. The cardboard core, with defective labels attached thereto, is then disposed of.

The problem with this is that not only is a complicated method being used to remove the faulty label but in addition the faulty labels are being placed on top of each other which makes it very difficult if not impossible to check the defective labels after removal and reconciliate the faulty labels.

The next two faulty label removal systems use vacuum drums to remove the faulty label from the web of labels.

WO 2008/012633 (Gironi and Ficalbi) describes an apparatus and method for rejecting irregular or faulty labels, in particular self-sticking labels, which is associated with a labelling machine. Again this apparatus is designed to remove labels from a label carrier band prior to application to an article. The labels are removed from the label carrier band by moving the label carrier band into close proximity with a drum which sucks the label from the label carrier band and which then fixes the defective label to a second label carrier band.

WO 2008/055052 (Merril and Goodwin) describes a label removal system for removing unwanted labels from a web of labels in a labelling machine. The labels are removed from the web by moving a rod element under the label web to move the label web close to a vacuum drum which then sucks the faulty label from the label web on to the vacuum drum where it is then transferred on to a second label web.

The problem with this is again that the method being used to remove the faulty labels is complicated, requiring the presence of vacuum drums which is not suitable for all labelling systems.

The last label removal systems all leave faulty labels on the label web rather than removing the faulty label.

WO 2005/111921 (Benton & Bisson), WO 01/00492 (Delmolino & Goodwin), WO 2005/102845 (Lenkl & Korzeniewski), wo 2005/120962 (Carver & Herman) and WO 2006/121387 (Dijkstra) describe an apparatus for selectively peeling a label from a label carrier band. In this instance, correct labels are removed from the label carrier band using a rotatable peel bar comprising a rotatable cylinder and blade.

Once a label has been peeled from the label carrier it is then applied to a product.

When a defective label is noted, the peel bar is rotated such that the label is not peeled from the label carrier band and is instead retained on the label carrier band.

GB-2425298 (Esposito & Borsos) and WO 2008/021597 (Angel & Glenski) describe a retractable peel plate assembly for peeling a label from a label carrier band. In this instance, correct labels are removed from the label carrier band using a retractable peel plate and applied directly to the product to be labelled. When a defective label is noted, the peel bar is retracted such that the label is not peeled from the label carrier band is instead retained on the label carrier band.

The problems with these systems is that the faulty label remains on the web of labels right up until the application to the articles. The system operates to stop faulty labels being removed from the web of labels and being applied to the articles and instead remain on the web. This means that there is no checking after the detection of the faulty label to make sure that the system has correctly stopped the label being applied to the article. In addition the spaces between the labels remaining on the web is inconsistent which causes issues for later reconciliation of the faulty labels remaining on the web of labels The present invention provides for an alternative system whereby the faulty labels are removed from the original web using retractable peel plate and transferred directly on to a second web allowing for easy reconciliation of labels and removal of the label prior to the label application stage. There is no need for complicated methods of removing the label using compressed air or vacuum drums as found in the art. The label is removed well before application stage. If desired, a secondary label check can be placed downstream of the removal to ensure no further faulty labels have passed the faulty label removal stage.

This method of faulty label removal is unique as it provides automatic and manual reconciliation as well as the benefit that the parent labelling system does not need to reduce operating speed to remove faulty labels.

The compensating action of the ejection mechanism and speed control between the web and collection substrate prevent interference with the labelling accuracy of the parent labelling system.

The collection substrate is controlled with respect to the velocity of the web on the parent system. This ensures space between the collected labels and so permits reconciliation and visual verification for the entire length of each collected label.

According to a first aspect of the present invention there is provided a faulty label sorting system for use in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles.

Identification of faulty labels, for example in a system for labelling articles comprising containers for pharmaceutical products may comprise identifying the faulty labels by opto-electronic means.

This invention automatically removes the identified (as faulty) labels from the label web before they are applied to the container, collects them on a secondary web, verifies removal electronically, reconciles removal and also allows easy visual verification, either by a secondary detection means or by hand inspection.

Preferably the means for removing the detected faulty label comprises a retractable peel plate.

Preferably the retractable peel plate is located on the non-label side of the first web of labels.

Preferably the retractable peel plate is in a retracted position the labels remain on the first web of labels and when the retractable peel plate is in a non-retracted position the label is removed from the first web of labels.

Preferably the means for removing the detected faulty labels further comprises first and second gate members located on the label side of the first web of labels.

Preferably the first and second gate members are fixed along the same axis and co-operate to form an aperture therebetween.

Preferably the peel plate is in a non-retracted position the peel plate is located in the aperture formed by the first and second gate members.

Preferably the retractable peel plate is connected via a beam to a compensating pin to enable the peel plate to be retracted.

Preferably the compensating pin and retractable peel plate are arranged such that the path length if the first web when the peel plate is in the retracted position is the same as when the peel plate is in the non-retracted position.

Preferably the secondary web is arranged to directly receive the detected faulty label from the first web of labels.

Preferably the secondary web moves relative to the web of labels such that when the detected faulty labels are received on the secondary web they are received at regular intervals.

Preferably the secondary web is provided with a label sensor for checking the detected faulty labels received on the secondary web.

Preferably the secondary web is provided with a nip drive for driving the secondary web. Advantageously this also acts to securely adhere the detected faulty label to the secondary web.

According to a second aspect of the present invention there is provided the use of a faulty label removal system for use in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles.

According to a third aspect of the present invention there is provide a method of automatically removing and reconciliating faulty labels in an automated labelling system of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, comprising the steps of: detecting a faulty label on the first web of labels using a detection means; directly transferring the faulty label from the first web of labels to a secondary web for reconciliation.

According to a fourth aspect of the present invention there is provided a method of automatically removing and reconciliating faulty labels in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles.

According to,a fifth aspect of the present invention there is provided a faulty label sorting system for use in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles; wherein the faulty label sorting system is incorporated into an automated labelling system.

According to a sixth aspect of the present invention there is provided a labelling system for use in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising a faulty label sorting system, the faulty label sorting system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

Figure 1 illustrates a plan view of the present invention; Figure 2 illustrates a plan view of the present invention when a label is not detected as being faulty and does not need to be removed from the first web; Figure 3 illustrates a plan view of the present invention when the label is faulty and needs to be removed from the first web; Figure 4 illustrates a plan view of the secondary web collection of the faulty label; and Figures 5 and 6 illustrates a plan view of an example label application stage downstream of the site of faulty label removal showing how the labels are applied to containers.

Referring now to the figures, Figure 1 shows a general plan of the invention.

Figure 2 shows the normal label path where no label ejection is necessary. The direction of travel is from right to left. The first web (5) with labels (6) attached is guided behind fixed gates (7,8) and over fixed guide pins (9,10). The peel plate (4) is held close behind the web (5) and between the fixed gates (7,8) in a retracted position. The first web (5) is held against the fixed guide pins by the compensating pin (1).

Figure 3 shows the label path when a faulty label has been identified and requires ejecting from the system. Faulty label ejection is achieved by the peel plate (4) being driven between the fixed gates (7,8). When the first web (5) is advanced the label (6) is peeled from the first web (5) ready for collection.

The peel plate (4) and the compensating pin (I) are joined by beam (3) and pivot about a point (2). The geometry of the peel and compensating items (1,2,3,4) is such that the first web path length shown in Figure 2 and Figure 3 are the same.

This ensures that the positional accuracy of the labelling operation on the parent labelling system is unaffected by the ejection system.

The peel plate (4) remains in the forward or unretracted position as shown in Figure 3 until an entire label has been removed from the first web.

Figure 4 shows the system for collecting the ejected faulty label. The secondary web (12) is driven at the same linear velocity, by an electronic control system, as the first web on the parent labelling system by the driven roller (18) and the pinching action of the nip roller (19).

The secondary web (12) is pulled off the roll (11) drawn around guide roller (13) to a plate (14) that is so positioned to meet the ejected label (15). The advancing secondary web (12) is drawn over roller (16). The tension in the advancing secondary web (12) produces pressure between the ejected label (15) and the roller (16) and in so doing adheres the ejected label (15) to the secondary web (12). As the ejected label (15) is drawn with the secondary web (12) its presence is verified by the label sensor (17). The change in state of the label sensor (17) will also confirm the adherence of the label and the motion of the secondary web. The secondary web and label pass through the nip drive (18,19) over a guide pin (20) to a driven collection spool (21). The collected faulty labels (15) on the secondary web (12) can be removed from the collection spool (21) for visual inspection, reconciliation and controlled disposal.

As can be appreciated the label sorting system of the present invention can be inserted into many automated labelling systems including both continuous labelling systems and non-continuous labelling systems.

Continuous labelling systems are systems where in a single step the label is applied and secured to the container. Non-continuous labelling systems are systems where in more than one step the label is applied and then secured to the container.

Figures 5 and 6 show one such continuous labelling system into which the faulty label sorting system of the present invention can be inserted. The faulty label sorting system of the present invention is not limited to such labelling systems and would be suitable to be inserted into other labelling systems.

Figures 5 and 6 show a labelling system downstream of the faulty label sorting system wherein the non-faulty labels (27) have remained on the first web and are now ready for application to a container (22).

The containers (22) travel along a conveyor belt (23) or the like to the label application stage wherein the containers (22) are directed between a drum (24) and a curved back member (25). The distance between the drum (24) and the curved back member (25) can be varied such that the distance is the same as the width of the container (22) that labels are being applied to. Adjacent to the container as it enters the gap between the drum (24) and the curved back member (25) is located the label application peel plate (26) which is in this labelling system stationary. The labels (27) continue along the first web (5) until they reach the label application peel plate (26) wherein the labels continue along the path towards the containers (22) and peel off the first web (5). The labels (27) are then applied to the containers (22) and fixed in place by the action of the containers being passed between the drum (24) and the curved back member (25).

This is only one such example of a labelling system that the present invention can be used in combination with and may be incorporated into many systems as determined by the labelling specialist.

Claims

Claims 1. A faulty label sorting system for use in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles.
2. A faulty label removal system as claimed in Claim 1, wherein the means for removing the detected faulty label comprises a retractable peel plate.
3. A faulty label removal system as claimed in Claim 2, wherein the retractable peel plate is located on the non-label side of the first web of labels.
4. A faulty label removal system as claimed in Claim 2 or Claim 3, wherein when the retractable peel plate is in a retracted position the labels remain on the first web of labels and when the retractable peel plate is in a non-retracted position the label is removed from the first web of labels.
5. A faulty label removal system as claimed in any of Claims 2 to 4, wherein the means for removing the detected faulty labels further comprises first and second gate members located on the label side of the first web of labels.
6. A faulty label removal system as claimed in Claim 5, wherein the first and second gate members are fixed along the same axis and co-operate to form an aperture therebetween.
7. A faulty label removal system as claimed in Claim 5, wherein when the peel plate is in a non-retracted position the peel plate is located in the aperture formed by the first and second gate members.
8. A faulty label removal system as claimed in any of Claims 2 to 7, wherein the retractable peel plate is connected via a beam to a compensating pin to enable the peel plate to be retracted.
9. A faulty label removal system as claimed in Claim 8, wherein the compensating pin and retractable peel plate are arranged such that the path length of the first web when the peel plate is in the retracted position is the same as when the peel plate is in the non-retracted position.
10. A faulty label removal system as claimed in any of the preceding claims, wherein the secondary web is arranged to directly receive the detected faulty label from the first web of labels.
11. A faulty label removal system as claimed in any of the preceding claims, wherein the secondary web moves relative to the first web of labels such that when the detected faulty labels are received on the secondary web they are received at regular intervals.
12. A faulty label removal system as claimed in any of the preceding claims, wherein the secondary web is provided with a label sensor for checking the detected faulty labels received on the secondary web.
13. A faulty label removal system as claimed in any of the preceding claims, wherein the secondary web is provided with a nip drive for driving the secondary web.
14. A faulty label removal system as described herein with reference to the accompanying drawings.
15. The use of a faulty label removal system as defined in any of Claims Ito 14.
16. The use of a faulty label removal system as described herein with reference to the accompanying drawings.
17. A method of automatically removing and reconciliating faulty labels in an automated labelling system of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, comprising the steps of: detecting a faulty label on the first web of labels using a detection means; directly transferring the faulty label from the first web of labels to a secondary web for reconciliation.
19. A method as claimed in Claim 16 using the system as defined in any of Claims 1 to 14.
19. A method of automatically removing and reconciliating faulty labels in a continuous labelling system as described herein with reference to the accompanying drawings..
20. A faulty label removal system as defined in any of claims I to 14 incorporated into an automated labelling system.
21. A labelling system for use in the automated labelling of articles in which labels having adhesive on one side and data on an opposing side are carried toward a site of label application by a first web, the adhesive side of the label being releasably adhered to the first web, the system comprising a faulty label sorting system, the faulty label sorting system comprising: a detection means for detecting a faulty label on the first web prior to application of the label to an article, a means for removing the detected faulty label from the first web and transferring each detected faulty label directly on to a secondary web prior to the site of label application, wherein labels which have not been detected as faulty remain on the first web and continue to the site of label application to be applied to the articles.