The New Labeller Generation from KHS: Innoket SE Labelling Machines

The presentational effect of the label relates equally to visual appearance and to the chosen label material. Wet glue, hotmelt, roll-fed or adhesive-pressure labels - the choice of different label materials and labeling techniques gives the product marketing department a multitude of options. The newly developed labeler Innoket SE from KHS represents the realization of all conceivable labeling requirements and, at the same time, provides plenty of future-proofing.

For the beverage, food, and non-food industries

Matched to the requirements of the sector, as well as high-performance applications with capacities of 75,000 bottles/h and more, the Innoket SE range provides particular flexibility for medium-sized companies, and special compact solutions for the food and non-food industries.

Modular design and hence great simplicity

The basic version of the Innoket SE labeling machine has been deliberately kept simple. It is comprised of a table construction and the central labeling carousel - matched to the system requirements in each case. This labeling carousel can be flexibly equipped with a wide variety of labeling stations.

Whether coldmelt, hotmelt, adhesive-pressure, or rollfed labeling stations – they are all doable. It is likewise possible to attach a camera system. The Innoket SE hence embodies a labeling concept with modular design, which has the advantage that all modules can be easily changed if new labeling requirements should arise within the organization.

Compared with the proven Innoket KL 2000 generation of labeling machines with a pre-defined location for every labeling station, which is retained for the whole life of the labeler, the Innoket SE provides a new kind of flexibility with its unit exchange system. Companies, who want to keep all their options open for the future, will find the Innoket SE eminently suitable.

There are also arguments favoring "fixed locations"

If labeling requirements are exactly known and no changes in the labeling process are envisaged at a later date, then investment in the proven KL 2000 generation of KHS labeling machines continues to be a viable option. The advantage here is that, due to the fixed location of each labeling station, there is no need for an exchange process when the dressing is changed. If a particular labeling station is not going to be used for a certain amount of time, the station can be simply disengaged. Another plus point is the lower cost of investment versus with the Innoket SE.

Servo drive technology is standard

Compared with the conventional solution using an Innoket KL 2000, the Innoket SE takes up less space in the plant due to the facility for flexible replacement of labeling stations. Each of the Innoket SE's labeling stations is equipped with servo drive technology. Where, in the past, a mechanical drive with a gearbox was used, there is now a corresponding servo drive. The number of mechanical drive components has been reduced considerably.

When labeling stations are changed, the software and computer can always synchronize the stations automatically. Mounting and removing stations is extremely easy. Simple coupling and decoupling at one of the station locations provided on the labeling carousel is all that is required. The Innoket SE concept includes placing each labeling station so that it can be positioned flush with the top of the table. An adjustable foot, which can optionally be positioned automatically or manually, compensates for any unevenness in the floor. This always guarantees accurate alignment of the station with the machine.

Different options of lower chuck control

Whether mechanically controlled cam rotation or VarioDrive – both types of lower chuck control are possible with the Innoket SE concept. Electronic VarioDrive bottle turret control provides maximum flexibility. In this case, the bottle turret, motor, and electronic equipment form a single unit and communicate directly with one another. Each individually required container rotation can be geared exactly to the container format and style of dressing. A further advantage of VarioDrive is that, due to the motor-driven lower chuck rotation, the length of the label to be applied is not limited by the machine pitch. Label lengths can extend beyond the machine spacing by programming further rotation for the particular style of container. Sheet-feed or roll-fed wrap-around labeling is therefore also possible.

In conjunction with a camera-based alignment system, VarioDrive achieves precise container alignment together with maximum labeling quality. With the Innoket SE, this can also be added in the form of a module to thus extremely easily solve even the most demanding labeling tasks. For example, the accurate application of a label in a special embossed area of the container, or the accurate placement of a no-label look label outside the glass seam.

Exact planning

If the decision is made to invest in the Innoket SE and thus to invest in maximum future-proofing, the maximum number of labels to be applied to a container must be determined first. This defines the necessary number of positions for labeling stations and the size of the machine.

Combined as required

The individual labeling stations can be combined fully in accordance with the requirements of brand and container. Roll-fed labeling with subsequent application of hotmelt labels, wet glue labels and adhesive-pressure labels, or only adhesive-pressure labels – all combinations are conceivable.

Proven wet glue labeling station

The wet glue labeling station provided with the Innoket SE is the proven labeling station from the Innoket KL 2000. When the wet glue technique is used, paper labels are applied with glue spread over the entire surface. One labeling station can apply several wet glue labels to the container simultaneously. Part of the Innoket SE concept involves rotating the station by means of a servo. The sequence of movement within the station is controlled by an external double cam race. Glue segments remove the labels gently from the labeling magazine and guide them with an optimum peeling angle to the gripper cylinder, which finally applies the label to the bottle. The chosen peeling angle results in minimal tensile forces on the label and also guarantees that even extremely sensitive label material is gently processed.

Overhaul not necessary until after 20,000 hours of operation at the earliest

KHS wet glue labeling stations are distinguished by a long service life. Overhauls are only required after 20,000 hours of operation at the earliest. Several factors are responsible for the long service life of KHS wet glue labeling stations. The first important feature is the rotation of the glue segments. This avoids vibration, overloads, and wear. Other aspects, which contribute to the long service life, include direct drive without additional gear stages, a conical coupling without play, and multiple labyrinth seals. Added to this is the advantage of the external oil circulation lubrication system. The amount and distribution of lubricant is exactly defined. All lubrication points are automatically monitored. This system ensures lubrication regardless of station rotation.

Another important aspect for the service life of the labeling station is sealing of the station housing by means of a multiple labyrinth seal to reliably prevent water from penetrating the insides of the station. For cleaning purposes, the labeling station is equipped with an integral hot water spray, which selectively flushes off the gluing segments as well as the glue drum. There is also no reason why intensive manual cleaning of the labeling station should not be carried out using the water hose if required.

Station redundancy or individual station - both are possible with adhesive-pressure labeling

The improved KHS adhesive-pressure labeling station of the Innoket SE applies self-adhesive labels. Paper labels can be used for adhesive-pressure labeling equally as well as plastic labels. The particularly spectacular no-label look is an excellent attention getter. Transparent adhesive-pressure labels are used in this instance. A particularly interesting and very flexible labeling option from a marketing standpoint since the labels appear to be printed on the containers.

The adhesive-pressure label materials are roll-fed. A final extremely sharp bend over a dispensing edge causes the label to peel off the label web for subsequent transfer to the container. A sensor located in the labeling station regulates the exact distance between label applications. The label is pressed against the container immediately after the dispensing edge and brushed on shortly thereafter.

Due to the slim design of the Innoket APL, it is also possible to connect the tandem station to only one designated station position on the Innoket SE. Station redundancy has the quite clear advantage that, in practice, there is no further downtime. When the roll on one labeling station has been used, the second labeling station continues to operate without any disruption. The redundant mode of operation means that the labeling process is almost 100 percent efficient while simultaneously maintaining full production speed.

Likewise possible on request: one adhesive-pressure labeling station per Innoket SE location. This is particularly advantageous with low labeling capacity or on the first entry into adhesive-pressure labeling. The very clear advantages of adhesive-pressure labeling are the lack of format parts for various label sizes and the highly attractive dressing.

Certain similarities of hotmelt and roll-fed labeling

Both the sheet-feed and the roll-feed method can be used to apply wrap-around labels If the hotmelt labeling method is used in conjunction with wrap-around labels, it is only necessary to apply glue to the start and end of the label, which is attractive particularly for economic reasons. In the case of labels fed individually from a magazine, a spot of glue is first applied to the container which is then used remove the label from the magazine. The glue strip for overlap adhesion is applied to the label end as it is pulled out of the magazine. The rotational movement of the container wraps the label tightly around the bottle, after which a strip of glue precisely sticks the overlapping ends together. Special plastic film labels can also be processed as well as the normal paper labels.

While paper labels are predominantly used with this labeling technology, plastic film labels are more prevalent with roll-fed labeling. The main difference is that the labels of the roll-feed method are on endless rolls. The label web runs from the roll over a controlled feed mechanism to the labeling station where it is cut exactly to length according to markings printed on the web. The process is monitored by a control sensor that ensures that the specifications are exactly adhered to. The labels are held in place on the cutter drum by a vacuum during the cutting process. A selective blowoff process then transfers the labels to the label drum where, like the cutter drum, the labels are held exactly in place by a vacuum. The cut label is transferred from the vacuum drum to the container using hotmelt. Application of glue to the leading and trailing edges of the labels and reliable label seating are ensured.

Compatibility is a given

Those that have previously used the proven Innoket KL 2000 generation of labeling machines, but who have now decided on the Innoket SE for reasons of maximum flexibility, will benefit from the fact that the same parts can be used for both machines. Whether application-dependent components such as the label magazine, segment shafts, and gripper cylinder, or other components such as the application elements and VarioDrive – all these components are also used on the Innoket SE.

Integrated control cabinet

Another advantage that has been retained with the Innoket SE concept relates to integrating the control cabinet into the machine paneling. This shortens the machine installation time on the one hand, and reduces possible error sources on the other, since no additional wiring is necessary between the machine and the control cabinet.

Improved accessibility

Accessibility to the machine has also been improved with the Innoket SE. The modular design enables labeling stations to be dismantled within a very short time. This allows thorough machine cleaning to be completed just as quickly as machine maintenance. The individual labeling stations can be serviced and tested separately at the same time if required.

Equipped for any future

Conclusion: With the newly developed KHS Innoket SE labeling concept, modular design leads to maximum flexibility to thus ensure a highest level of future-proofing. Whichever labeling techniques are required by the consumer in the future, the Innoket SE is equipped to provide them. The investment cost in a new labeling station is minimal compared with the investment in new labeling technology. At the same time, the Innoket SE has the advantage that existing labeling stations can be used time and time again, whenever the consumer changes his mind, and labeling trends can be dealt with at any time without any problems whatsoever, and, above all, speedily.