Wrap-Around Pharmaceutical Application

A medical device manufacturer wanted to automatically apply two unique 4 X 6-inch bar code labels to its corrugated shipping containers at an approximate rate of 1 to 2 labels per minute. Label placement accuracy was an important consideration.

FOX IV Technologies provided a complete turnkey system that included a FOX IV Repeater and a customized FOX IV Sidewinder mounted on a standard FOX IV 4051 label printer applicator. The 4051 Standard is based on Intermec thermal transfer 406 dpi print technology. An 8 megabyte memory upgrade was provided.

The "Repeater" is an optional apply system used to apply two labels to a box or product; in this case, on the front and side. After exiting an automatic taper, product is metered by a box feeder, or brake, that holds the box until the preceding box is released from the labeling area. Four photoeye sensors stationed along the conveyor frame trigger the operation of the LPA. The sensors locate the product on the conveyor, ready the LPA for the print-and-apply operation, stop the box in, and release the box from, the apply station.

The labels are applied by the "Touch-blo" method, which provides accurate label placement and strong adhesion through use of compressed air to blow the label onto the product once the applicator touches the surface. To ensure superior adhesion following label application the Sidewinder" rolls the labels.

The custom material handling system consists of: an 8 foot section of powered belt conveyor, built using a modular, extruded aluminum framing system; guide rails for positioning the product or box on the conveyor; a box feeder or box brake; a box stop; and two single color fault/warning beacons (one on the conveyor and one in a remote operator room).

The system has been designed to prevent a box from feeding into the system under certain conditions: if the LPA faults (such as out-of-labels, label not on pad or an out-of-sequence condition); if the Repeater arm is not extended in the ready position; if the exit gravity conveyor backs up into the label apply station. Labeling continues unless the Emergency Stop button is activated, a safety E-Stop mat is stepped on, or the LPA faults. In these cases the conveyor stops and both fault/warning beacons flash.

In addition to hardware, system integration, installation, start-up and training assistance were provided. A FOX IV label printer applicator cleaning kit was also part of the system package.