How to Automate your UPC Labeling and Tracking Process
Keeping track of inventory is one of the top priorities of internal operations for any business. A common way stores and companies track inventory is with barcodes which can be scanned to identify the product and its price. With barcode labels, products can be tracked from production to the point of sale, or even to contact a customer if there is a major recall on the product. There are two major types of barcodes used in the world.
Universal Product Codes (UPC)
Universal Product Code (UPC) is a unique 12-digit number assigned to a product or item by the Global Standards Organization (GS1). The GS1 manages global barcode standards, as companies cannot create their own UPC numbers. UPCs are widely known as the primary way businesses track inventory. The basis for UPCs was created by a group of trade associations from the grocery industry to increase efficiency while stocking shelves and decreasing check-out times at their grocery stores. Now, each industry dictates its own requirements for the UPCs. Though not legally required, UPCs are usually necessary to sell through traditional retailers and online marketplaces like Amazon, Walmart, and more.
UPCs are made up of a country code number (the code for USA and Canada is zero (0)), a company number code, and a product number code. With these parameters, there are billions of UPCs in the world with each company having hundreds to thousands of UPCs in its inventory. Each product and its variations need its own unique UPC code. For example, for every t-shirt design, there are size variations from extra small to extra large, meaning a company needs five UPCs (one for each size) for just one t-shirt design.
International Article Numbers (EAN)
The rest of the world uses International Article Numbers (also known as European Article Numbers or EANs) to track their products. With the popularity of UPCs growing in other countries, EANs were created to increase the number of codes for the different European, Asian, and African countries. The GS1 organization also assigns the EANs to companies. EANs have 13 digits and countries have specific codes while the USA and Canada’s country code is zero (0). Multinational companies can have both UPCs for their products sold in USA and Canada and EANs for products sold internationally.
Best UPC Practices
The main advantage of barcodes is their scannability, made for quick data capture and unobtrusiveness on the packaging. The barcode has to be readable otherwise it will not scan and important data tracking data can be lost. Let’s quickly cover some best practices and standards for your UPC labels:
To guarantee readability, UPCs must follow specific design standards. First, The area on the left and right side of the UPC barcode is required to be free of all printing. This area is known as the ”Quiet Zone”. Quiet zones are required on both ends to read the barcode from either direction to prepare the scanners for the barcode and tell the scanner when to stop.
The level of contrast between the background and barcode bars is important to maintain readability. In the same vein as contrast, the transparency of the package can cause problems. Transparent packaging, such as plastic bags or containers can be problematic as barcodes have trouble being read on the transparent material. It’s recommended that the background of the UPC on transparent packages be opaque white to increase the contrast with the dark bars.
The standard size of a UPC code is 1.469 inches wide by 1.02 inches high, including all the numbers on the bottom. The maximum recommended size, 200% of the standard size, is 2.938″ w x 2.04″ h. The minimum recommended size is 80% of the standard size or 1.175″ w x .816″ h.
The best location to place UPC barcodes on the product is anywhere that is easy to scan and find. Generally, UPCs are located on the bottom or backside of a product so the barcode doesn’t conflict with the packaging design. Though recent advancements in sensor and scanning technologies have boosted a new design trend of creatively incorporating the barcode into the packaging’s design. These vanity barcodes are still functional but they come in odd shapes and different colors and extraneous designs. But most companies stick to the standard design and many industries set their own specific standards for design and location.
Labeling
Large companies with mass-marketed products often integrate UPCs into the packaging design but small businesses might not have the resources. Labeling is a fast and cost-effective way to apply UPCs to your products. MFT Automation has a wide range of high-performance labelers for automating your UPC and barcode labeling process. From high-speed labelers to print and apply labelers, MFT Automation has a barcode labeler to fit your labeling needs. Compact and modular, our labelers are built to seamlessly integrate into existing production lines.
Impresso Series
MFT Automation’s Impresso Labeler is small and compact for maximum flexibility and can be easily integrated into existing production lines or exist as a piece of standalone equipment. The state-of-the-art, high-performance labeler features a 1000-watt brushless servo motor for efficient unwinding and rewinding and durable stainless steel shafts provide maximum life expectancy.
High-Speed Modular Series
Most companies have a high volume of products to label with barcodes and UPC labels. A high-speed barcode label applicator will help you keep up with demand. With independently powered, synchronized servo drive motors for unwind, rewind, and drive, the High Speed Modular (HSM) series can function at high speeds while maintaining accuracy and precision while placing labels. Flexible and compact, the HSM series can be easily integrated into existing systems or be a standalone piece of equipment without sacrificing space in your production lines.
Print and Apply Labeler
The MFT Print and Apply Labeler system prints and adheres labels to most flat surfaces from packaging, and cartons to folders, pouches, and more. Print and apply labeling is a good technique for barcode labeling as it can print UPC and barcode labels on demand. The system has a modular design with the ability to use different print engines for the customization of print quality. Customization gives the option to match the printing engine to a customer’s existing print engine so there is no learning curve in maintenance for a new print engine, making it perfect for labeling applications.
Track and Trace System
Integrate one of our high-performance labelers into our innovative Track and Trace system. The Track & Trace system offers turnkey product handling for serialization coding/printing, and an inspection and rejects system providing a trackable data file. A powerful infrared sensor allows for accurate count using double-detect and overlap detection. This integrated manufacturing system is equipped with a highly adaptable software package that ensures flexible and precise controls.
MFT Automation
MFT Automation has been helping customers design, build, and integrate high-performance automation solutions for over 25 years. MFT Automation’s equipment, systems, and services are known for their flexibility, accuracy, and performance. Our success is made possible by our engineering-oriented and customer-driven approach to finding the best possible automation solution for customers’ applications.
With an abundance of in-house resources including Mechanical Engineering, Electrical Engineering, Software Engineering, and a machine shop with modern CNC and lathe machine tools, we work with customers from the first solution draft to installation and integration. Contact us with your latest automation challenge, online or call us at 1-651-427-1255.
Food Packaging Trends of 2022
The pandemic, resource and labor shortages, and more have noticeably altered the food packaging industry this past year. With some of the new trends being years in the making and others skyrocketing to the top with the recent circumstances, here are some of the top food packaging trends for 2022.
How to Automate Your Pouch Packaging Process
In many industries, heat-sealed pouches have become an efficient and cost-effective way to send product samples, and sometimes even products themselves to customers. Heat-sealed packets are highly versatile as they can be made with many different materials and come in many different sizes. Because of their versatility, they are used in many industries for many different kinds of products. And a new demand for custom samples and products has risen in consumers that make re-sealable and disposable pouches as a good way to fulfill lot size one orders for small items. The small and portable pouches are also perfect for the current grab n’ go culture. Anything from snacks to beauty creams to medicine, the pouches can hold a little bit of everything and fit easily inside bags. Looking to start using heat-sealed sample packets or looking to automate your pouch packaging process? From verifying barcodes to labeling pouches, there are many opportunities for automation. Here’s our guide on automating your pouch packaging process.
Where to Use Hygienic vs Washdown for Better Food Safety
In the food and beverage industry, food safety is a top priority. Keeping a sanitary environment at all stages of the food packaging process is vital for the safety of customers and the bottom line of the business. A joint study by the Food Marketing Institute and Grocery Manufacturers Association found that on average food recalls cost food companies $10 million in direct costs, this number doesn’t even include the damage to the brand’s reputation and the loss in sales while the company works to regain public trust. Investing in food safety as a business could save millions of dollars in legal damages in the long run.
Labeling on the Production Line: 5 Successful Ways to Print
When identifying which print and label options to use on your production line, there are a few factors you should keep in mind before making your decision. The first is your business model; you’ll want to be sure the printer and label application you choose supports your company’s processes and offers an opportunity for profit. You’ll also want to take into consideration the type of product or products the label will be printed on. The needs of your product(s) should directly influence which print/labeling method is right for you.
In this blog, we dive into the top five print and label methods to consider adding to your production line. Integrating equipment into your automation process that supports these efficient labeling and printing techniques is an excellent way to increase efficiency, output, and quality on your production line.
What you Need to Know about Tax Stamp Application
In order to understand tax stamps and the process for ensuring secure and safe tax stamp application, there are a few components you must first understand. In this blog we’ll cover what a tax stamp is and what makes it different from other consumer stamps. We’ll also share common industries who may use tax stamps and identify automation equipment that could increase your packaging efficiencies.
3 Techniques for Successful Automatic Label Application
If you’re looking to learn more about proven labeling techniques for automatic labeling and what’s needed for your label applicators, this blog is a great place to start. While there are many techniques in the industry, wipe-on labeling, tamp label applicators, and blow-on labels are three techniques we recommend for successful automatic labeling. Let’s dive into each technique with a bit more detail.
1. Wipe-on Label Applicator
Sometimes referred to as “merge” labeling; wipe-on labeling is where a label is dispensed in the same direction of flow as a product when a label is being applied. This is an automatic labeling technique that is widely used in the industry but requires precise set-up for optimal production speeds and quality output. It is also used for products with irregular shapes and surfaces that are not flat (source).
Wipe-on label applicators typically require the base product to be moving and consistently presented to the labeler. While the product moves towards the labeler, a free rotating roller or brush is used to aid the transfer of the label onto the moving product. From there an encoder can be used to track the speed of the product the label will be applied to so the labeler can apply accurately if the product speed might vary.
For this technique to be successful, your automatic labeler should have either a single axis or multiple axis motor. A single motor will assist with unwind, rewind, and drive; however, it will likely require clutching mechanisms for the unwind and rewind functionality. Whereas a multiple axis motor separately powers the unwind, rewind, and drive.
High-Speed Applications
For wipe-on labeling applications requiring higher speeds, a vacuum box or powered unwind may be implemented. (See the third technique to learn more about vacuum/blow boxes and blow-on labeling.) To meet these high-speed and tight accuracy requirements, a second stage may be added to the labeler such as:
Vacuum belt with motor drive: this option allows the label to be dispensed with the adhesive open (non-adhesive side facing the vacuum belt). The vacuum belt can then adjust position or speed to accurately apply the label such as using Multifeeder’s Accutipping controls.
Driven rotary vacuum wheel: this can transfer the label from the labeler to the product in a second stage for added speed or accuracy, similarly using servo controls such as Multifeeder’s Accutipping controls.
2. Tamp Label Applicator
A tamp applicator is a contactless technique for applying smaller labels on products. It is most commonly used on print and apply labelers; however, this technique can also be used on wipe-on label applicators for 3D products or hard-to-reach label placements (i.e. recessed areas). MFT 150pa Print and Apply Automatic Label Applicator
Tamp labelers place the label onto an air cylinder tamp pad or vacuum tamp pad before placing the label onto the product. As the product moves down the conveyor, a pressure sensor (such as Multifeeder design) can be used to indicate if the tamp pad comes into contact with the product. This is especially valuable for variable height products or more intricate products. Such products may also benefit from a complex tamp pad that can place a corner label on more than one surface.
To support a complex tamp pad, a second air cylinder or a hinge (spring-loaded or gas shock) may be required for the second side. A pneumatic style smart tamp or heavy-duty smart tamp could also be used to prevent any tweaking or sensitivity to dirt; learn more about the smart tamp we use in the MFT 150pa Print and Apply Automatic Label Applicator. Additionally, a tamp pad may feature vacuum to hold the label while an airblast is used to release the label onto the product.
3. Blow-on Label Applicator
This sophisticated technique is sometimes used to replace the industry-favorite wipe-on labeling; although it is slightly less precise. Blow-on label applicators use a controlled blast of compressed air to place labels at high application rates. (source 1, source 2). This technique is commonly used for blow labels on coupons and other high-speed applications that require a contactless application (i.e. glass or other fragile products).
A blow box or vacuum box can be used in a similar way when paired with a wipe-on labeler. Oftentimes the vacuum/blow box uses a muffin fan to create a vacuum effect by holding the label to the bottom surface of the transfer device. The wipe-on labeler will index the label onto the bottom surface of the vacuum/blow box, which is then held in place by vacuum. When a product traveling below the box gets to the location the label is to be applied, an air blast releases the label onto the product below. This feature allows the labeler to be placed either in-line or perpendicular to the base product flow depending on label orientation requirements.
Defining which automatic labeling technique is best for your product or application can depend on a series of variables. If you’re interested in learning more about these techniques and other labeling solutions for your product, we’re happy to help. Get in touch with one of our automation and labeling experts by contacting us here or check out some of our labelers here.
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Tags: Labelers, Integrated Systems