Dual Cartridge Labeling Machine Operation Manual: Setup to Maintenance

1. Key points for installation and layout

Where you place the machine determines half of its effectiveness:

1. Place it after filling, before packaging

   • Optimal workflow: Filling → Resting (for adhesive to stabilize) → Labeling → Boxing/Packaging.

   • Leave a 2-meter buffer zone between the labeler and filler for temporary storage.

2. Meet environmental requirements

   • Level floor: Check with a spirit level. Vibration occurs if uneven.

   • Stable power: Use a dedicated circuit, avoid sharing with other high-power equipment.

   • Temperature/Humidity control: Ideal is 15-25°C, humidity below 70%.

3. Leave sufficient space

   • Leave 1.5 meters of operating space in front.

   • Leave 0.8 meters on each side for maintenance.

   • Leave 0.5 meters behind for feeding label rolls.

2. Rapid training method for operators

Train novice operators in this sequence; they can work independently within a week:

Day 1: Safety & Basics

• Identify all safety features: Emergency stops (3 locations), guards, light curtains.

• Learn the correct startup/shutdown sequence.

• Master the correct orientation for placing cartridges.

Day 2: Routine Operation

• Learn to change label rolls (most important!).

• Practice calling up different product specs on the touchscreen.

• Master resetting and reading the production counter.

Day 3: Parameter Fine-tuning

• Learn to adjust the 3 main label position parameters: forward/back, left/right, angle.

• Practice fine-tuning based on actual cartridge conditions.

• Record the effects before and after adjustments.

Day 4: Simple Maintenance

• Learn the 6 key areas for daily cleaning.

• Master lubrication points and intervals.

• Learn to replace the sponge pad on the labeling head (consumable part).

Day 5: Fault Response

• Memorize the handling methods for the 5 most common faults.

• Practice reading alarm messages and historical logs.

• Simulate the correct way to communicate when calling for service.

Training Assessment Criteria:

• Can change a label roll within 5 minutes.

• Can complete a product changeover within 10 minutes.

• Can independently handle 3 types of common minor faults.

3. Techniques to boost production efficiency

Operating the same machine this way can increase output by 20%:

1. Use large label rolls

   • Use 1000m rolls instead of 300m rolls.

   • Reduces roll changes by 2/3, freeing up 3+ production hours monthly.

   • Larger rolls have a lower unit cost.

2. Batch load cartridges

   • Don't load one by one; use a container to load 20-30 at once.

   • Operators can perform other auxiliary tasks simultaneously.

   • Reduces walking time and physical strain.

3. Schedule concentrated changeovers

   • Group products of the same specification for production runs.

   • Example: Produce only specification A in the morning, B in the afternoon.

   • Aim for no more than 2 changeovers per day.

4. Utilize alarm warnings

   • Set low label warning for when 100 meters remain.

   • Set production target alarm to notify when shift goal is met.

   • Set runtime reminder to prompt a break after 4 hours of continuous operation.

5. Prepare thoroughly

   • Move the day's required label rolls next to the machine before starting.

   • Print the specification parameter sheet and post it on the machine.

   • Have cleaning tools and lubricant ready.

4. Key points for matching labels and cartridges

Poor labeling is often not the machine's fault:

1. Label material selection

   • Use matte labels on glossy cartridges, glossy labels on matte cartridges.

   • For surfaces with slight adhesive residue, choose labels with stronger adhesive.

   • Use heat-resistant labels for high-temperature environments.

2. Label size design

   • Label width should be 2-3mm narrower than the labeling area.

   • Precisely measure label length; best to test with a sample first.

   • QR code size should not be smaller than 5x5mm.

3. Cartridge pre-treatment

   • Let cartridges rest for 1 hour after filling before labeling to stabilize the surface.

   • For obvious adhesive residue, gently wipe with an alcohol-soaked non-woven cloth.

   • Test label 5 units before starting batch production to confirm results.

5. Stage quality control

Ensure every cartridge label is合格 (qualified):

Stage 1: First-Article Inspection

• Inspect the first 3 cartridges carefully after daily startup and each changeover.

• Check: Position, smoothness, information accuracy.

• Inspected by: Operator + Quality inspector (dual confirmation).

Stage 2: Mid-process Sampling

• Randomly sample 5 cartridges per hour.

• Focus check: Are label edges lifting?

• Record sampling results on a form.

Stage 3: Batch Review

• Before boxing each batch, check the last 10 units.

• Verify consistency of batch number and expiry date.

• If issues found, conduct a 100% inspection of that batch.

Handling Common Quality Issues:

• 3 consecutive不合格 (unqualified): Stop machine, inspect, adjust parameters.

• Batch label wrinkling: Try a different label roll.

• Progressive misalignment: Clean sensors, re-calibrate position.

6. Cost control details

Small details save big money:

1. Label costs

   • Negotiate discounts for bulk purchases.

   • Optimize label size to reduce waste.

   • Use standard size labels to avoid custom orders.

2. Electricity costs

   • Power off completely (not just standby) when not in production.

   • Regularly clean machine cooling fans for efficient heat dissipation.

   • Avoid frequent start-stop cycles; continuous runs are more energy-efficient.

3. Maintenance costs

   • Buy consumables (sponges, blades) in bulk.

   • Learn to replace simple components yourself.

   • Sign a maintenance contract with the manufacturer; cheaper than per-call service.

4. Labor costs

   • One operator can manage multiple machines (if output allows).

   • Cross-train operators to be versatile, reducing dedicated personnel.

   • Schedule shifts rationally to avoid overtime.

7. Data recording and analysis

Good records make management easier:

Daily Log (filled by operator)

• Startup time, shutdown time

• Shift output,合格 quantity

• Number of changeovers, downtime and reasons

• Label rolls used, remaining quantity

• Abnormal situation records

Weekly Summary (filled by team leader)

• Weekly total output, daily average output

• Equipment utilization rate (actual runtime / scheduled runtime)

• Label waste rate

• Summary of main fault types

• Improvement suggestions

Monthly Analysis Report (for supervisor)

• Monthly efficiency trend analysis

• Cost analysis (labels, electricity, repairs)

• Comparison data vs. manual labeling

• Next month's产能 (capacity) forecast

• Equipment maintenance plan

8. When to consider upgrading equipment?

These signs indicate an upgrade is needed:

1. Insufficient capacity

   • Machine runs at full capacity daily but still can't meet orders.

   • Frequent overtime is required to complete tasks.

2. Unstable quality

   • Increasing customer complaints about labeling.

   • Qualified rate持续下降 (continuously declines) and can't be improved via adjustments.

3. Uneconomical costs

   • Annual repair costs exceed 15% of the machine's value.

   • Energy consumption is significantly higher than newer models.

4. Insufficient functionality

   • Need to apply more label types.

   • Customer requires adding traceability QR codes.

   • Need to interface with a new management system.

Upgrade Advice:

• First, ask the original manufacturer to assess if the existing machine can be upgraded/retrofitted.

• Compare the cost and effect of upgrading vs. buying new.

• Consider equipment depreciation and tax incentive policies.

Final Important Reminder:
How well a labeling machine performs is 30% dependent on equipment quality and 70% on usage management. Even the best machine needs correct operation and careful maintenance. Establish a simple management system, train responsible operators, and regularly summarize and improve. Your labeling machine will then continue to deliver maximum value.