How to automatically label cartons of varying heights?

IMA FlexiMate eLinear is a modular Print & Apply system designed as a universal solution for automatic product labeling in industrial and logistics processes. The labeler combines industrial label printing with precise application on stationary or moving products. This device is available from Etisoft with Zebra or Sato print modules. In this article, we describe how to automatically label cartons of varying heights, which technical solutions make this possible, and why such a system works well in logistics, e-commerce, and industrial processes.

Print & Apply labeler for products of varying heights

Technical specification and variants of the Print & Apply labeler

The FlexiMate eLinear system features a robust construction made of anodized aluminum and stainless steel. This ensures corrosion resistance and durability in demanding industrial environments.

The key technical parameters include:

• Orientation and liner width: The system is available in right-hand or left-hand versions. It supports labels with a liner width of 4 inches (up to 110 mm) or 6 inches (up to 160 mm).
• Applicator stroke: The user can choose an arm with a nominal stroke of 250 mm, 350 mm, 500 mm, or 800 mm. The applicator arm is not pneumatic. Its movement (extension and return) is controlled by precise stepper motors.
• Application methods: The device offers Tamp (contact) and Tamp & Blow (non-contact by air blow) application modes.
• Performance and precision: The system achieves performance of up to 60 cycles per minute, maintaining a typical application accuracy of +/- 1 mm.
• User interface: Operation is performed via an intuitive 7-inch touch LCD panel with a resolution of 800 x 480 pixels, resistant to splashes.

Automatic label application on cartons of varying heights

FlexiMate eLinear is ideal for processes where products of different dimensions appear on the same production line, which is typical for modern logistics and e-commerce. The device offers two main solutions that enable automatic adjustment to carton height:

1. Optical proximity sensor (Variable stroke sensor): Mounted directly on the applicator pad, it allows non-contact label application on products of varying heights without the need for manual setting changes. The label is applied when the sensor detects the carton surface at the nearest possible point.

2. Laser height measurement sensor (Laser measurement sensor): This advanced solution allows dynamic definition of the applicator stroke. The sensor measures the height of the incoming product and sends a signal to the system. The system then extends the arm to a height corresponding to the product, reduced by approximately one centimeter, after which the label is blown onto the surface.

Additionally, for uneven surfaces and soft packaging, the system can be equipped with a dedicated FlexPad applicator pad. Thanks to a spring joint and damping system, the pad adapts to the shape of the product. This ensures better label adhesion on irregular surfaces.

What are the advantages of working with laser height measurement?

Using laser height measurement in the FlexiMate eLinear system offers a number of advanced benefits that significantly increase the efficiency and precision of automatic labeling, especially on lines with a high variety of products:

• Dynamic applicator stroke adjustment: The laser sensor measures products of different heights and dynamically defines the stroke of the applicator arm on this basis. As a result, the system automatically extends the arm to a height corresponding to the specific product (usually reduced by about one centimeter), eliminating the need for manual machine adjustment when changing the product batch.
• Maximum application precision: The use of a laser ensures that label dispensing occurs when the product is at the nearest possible point relative to the applicator pad. Shortening the distance between the pad and the product at the moment of blowing minimizes the risk of label displacement caused by airflow or product movement.
• Handling products with highly irregular shapes: Advanced sensor settings allow continuous reading of product height and its changes during the cycle (between the trigger for extension and the blow). The system can be configured to position the applicator pad at the lowest height measured up to that point, which is crucial for products with uneven or variable surfaces.
• Protection against collisions and damage: Laser measurement makes it possible to activate safety functions such as automatic retraction of the applicator pad if the sensor detects that the product height has suddenly increased above a defined threshold. This prevents the arm from hitting the product and potentially damaging the applicator mechanism.
• Data emulation capability: The system allows sensor operation to be emulated through commands sent via communication interfaces. This means that product height data can come from external data sources or higher-level systems, which facilitates integration in fully automated logistics centers.

Thanks to these features, laser height measurement makes the FlexiMate eLinear an ideal solution for industries such as e-commerce and logistics, where each successive carton on the conveyor may have different dimensions.

Labeler for cartons of varying heights – target industries and processes

Thanks to its modularity and adaptive functions, FlexiMate eLinear is an ideal solution for:

• Logistics and warehousing: Labeling parcels and grouped packages of different heights.
• Food and chemical industry: Marking bags (e.g. with pellets or pet food) thanks to the extra-stroke function, which allows additional pressure to be applied to soft surfaces.
• High-intensity processes: The ability to operate in Tandem (Zero Down Time) configuration allows two devices to work together, eliminating downtime related to label roll replacement.

In summary, the FlexiMate eLinear system combines high mechanical reliability with intelligent electronic control. This makes it one of the most versatile Print & Apply devices on the market.

If you are looking for a Print & Apply system that can handle products of varying dimensions and is ready for integration with your line, contact us. We will help you choose the right solution and tailor it to the specifics of your process.