We’re all booked! Come and visit ATD Marking Systems on stand G10 at this year’s PPMA Show being held at the NEC Birmingham on 1st – 3rd October 2019. ATD will be displaying its extensive range of industrial coding and marking systems including the Leibinger Jet3UP Continuous Inkjet Printer and ATD’s own IP8000 High Resolution Inkjet Printer among others.
The PPMA Show is one of UK’s largest processing and packaging machinery exhibitions and covers the full spectrum of the industry; including food, beverage, pharmaceuticals, household products and toiletries, as well as contract packers and more. (more…)
Can-pack, one of the UK’s largest manufacturers of aluminium cans for the beer and beverage industry, approached us at ATD for a solution to a unique requirement for can printing.
Having one of the world’s fastest aluminium can production lines, with productions speeds of up to 8m/sec, Can-pack produces 54 cans every second. Their can printing requirement was to print onto the base of each can using an invisible UV readable ink. There were many issues to overcome, mainly the speed of production and the temperature of the cans.
Their production line set up has 15 forming stations and within each forming station is a forming star wheel holding 12 cans. The star wheels rotate at up to 8 metres per second and transfers each can from one star wheel to the other and so on down the can forming line.
The location of a can on the forming star wheel is synchronised so that can position 1 on the first forming star wheel is the same as can position 1 on the last forming star wheel.
Canpack’s can printing requirement of applying the invisible UV readable code to the base of each can meant using sequential numbers from 01 to 12 to coincide with the can position in the star wheel and continuously repeat this sequence.
At ATD, we suggested the solution was to use the Leibinger Jet 3 UP printer, configured with their unique sterilisable UV readable ink. Can-pack were keen to hear more and invited us to visit them to conduct a full trial.
The trial was very successful, however, there were a number of engineering challenges we had to overcome. The first being how to detect the chamfered bottom edge of a reflective aluminium can travelling at 8m/sec and with a detection requirement of 54 cans per second. It was a tricky one, but working closely with our supply partner OEM Ltd, and after testing a number of their laser detectors, we found a reliable solution.
The second challenge we faced was synchronising the printed sequential number with the correct can position. We were able to solve this by attaching a metal plate to the end of the star wheel drive shaft and using an inductive detector to reset the Leibinger’s sequential counter. The variable speed of the production line as it accelerated and decelerated from zero to 8m/sec was synchronised with the Jet 3UP CIJ printer, by connecting a shaft encoder to the star wheel drive shaft.
Lastly, the environment where the Jet 3 UP print head is installed is very harsh, the temperature rises to 40ºC and the moving parts are well lubricated. There is the potential for the lubrication to enter the Jet 3 UP print head. This was another ticky issue for us but we were able to overcome it by installing a pumped air supply directly into the print head cavity.
The pumped air provided a continuous over-pressure within the print head cavity, all whilst the printer and production line is running, preventing lubricant from entering the print head and additionally providing cooling. This over-pressure system is a standard cost option for the Jet3 UP printer.
The results we were able to achieve completely hit the spot. Printing is clearly readable under UV light and the Jet 3 UP has been running reliably and successfully for a number of months now.
Can-pack has even requested additional Leibinger Jet 3 UP printers for their other production lines.
See the speed of the process for yourself here:
For further information please contact the ATD sales team on +44 1858 461014 or email: firstname.lastname@example.org.
ATDs success in the wallboard industry continues to grow. ATD has installed more of its latest generation high resolution wallboard stack printers in plants in Hungary and Finland, adding those already installed in France, Belgium, Germany, Poland and Romania. (more…)
We have recently worked with BAE Systems Plc, to review their munitions packaging printing solution. BAE, are a British multinational defence, security and aerospace company with headquarters in London and operations worldwide.
BAE produce a number of munitions products that each require different messaging, text and logos on the cardboard outer packaging. (more…)
We have recently installed a bespoke publication printing solution for a commercial print house in Dorchester. Henry Ling Limited, is a leading manufacturer of journals and books. They came to us to solve a problem they were experiencing with their production process. (more…)
We were delighted to work recently with the, Burger Manufacturing Co Ltd (BMC) on a new style of carton printing they needed to implement.