Downtime caused by roll changes costs time, money, and productivity. HERMA offers three solutions designed to achieve a common goal: a continuous labeling process without production-related interruptions. The EasySplicer and the AutoSplicer ensure an uninterrupted supply of label tape, regardless of the labeling technology used. The HERMA 500 with its redundancy function, not only ensures a continuous supply of labels but also protects the labeling process itself against malfunctions and outages.
Whether you’re planning a new production line or looking to optimize an existing system, all three solutions can be flexibly integrated into a variety of system configurations.
Three solutions – one goal: continuous labeling
EasySplicer – simple and secure
To ensure continuous production, the HERMA EasySplicer is equipped with two unwinders and a label buffer. This allows label rolls to be changed with no downtime—unlike with previous models. To achieve this, the two label rolls are arranged vertically, one above the other. The currently active label tape is guided over a splicing table and secured there when the tape ends. Because the EasySplicer is equipped with a label buffer, the labeling machine continues to run even after the tape has ended. An operator can perform the splicing process simultaneously so that the new label tape is spliced onto the secured tape end before the buffer is emptied. Integrated photoelectric sensors detect when a roll is nearly empty and trigger a signal light, giving the operator enough time to prepare for the splicing process.
AutoSplicer – automatic and reliable
The HERMA AutoSplicer features two roll dispensers. While the label tape from one roll is being processed, the second roll is already ready for the next changeover. As the active roll nears the end, the splicer automatically joins the end of the label tape to the prepared label tape from the new roll. The new optional cutting system now enables uninterrupted roll changes, even when the label web is firmly attached to the roll core.
Meanwhile, the labeling process continues. Afterward, the operator can remove the empty label core and prepare the new label roll on the free take-up unit.
This simply needs to be done in time before the label tape runs out again—the actual splicing process is fully automatic.
HERMA 500 – maximum availability
Reliable, nonstop labeling with the HERMA 500’s integrated redundancy feature. Two HERMA 500 labelers connected in series can take turns operating when a roll ends or in the event of other malfunctions, because they communicate directly with each other. This ensures reliable processes: it prevents both unlabeled and double-labeled products. The nonstop operation feature can even be activated retroactively* via a code and is suitable for all types of labeling. An additional PLC is not required. This makes the redundancy function equally appealing to machine builders as well as to operators of these machines or labelers.
* Technical requirement: The labelers must be running the latest firmware, have a CAN bus connection, and use mechanical unwinding and rewinding units.
* The EasyCutter is a useful addition to the EasySplicer and AutoSplicer. It replaces the rewinder by sucking up, shredding, and collecting the empty carrier tape while production continues uninterrupted. Manual intervention is eliminated, operating effort is reduced, and system availability increases.
** The production downtime due to roll changes is eliminated by all solutions; however, the effort required for the manual task of changing the label tape varies.
A Head Start That Pays Off
A simple real-world example illustrates just how significant the savings potential can be:
A production line with ten roll changes per shift and an average changeover time of three minutes loses about 30 minutes of production time per shift due to manual operations alone.
In a three-shift operation, this corresponds to a production downtime of:
- about 90 minutes per day,
- over 7 hours per week
- and more than 350 hours per year (based on 47 production weeks).
With automatic roll changes during operation, a large portion of this time can be put to productive use. Operating personnel can also focus more on value-added activities.
Of course, the actual potential savings in each individual case depend on production speed, roll size, and system configuration; but they are significant in any case.
Introducing our non-stop solutions
Compelling benefits
For labeling without stoppages or downtime, HERMA solutions can be easily integrated into existing systems and customized to meet specific needs. After a quick setup and training, the benefits are clear:
- HERMA Nonstop solutions prevent downtime during roll changes and ensure a continuous labeling process.
- With this uninterrupted production, rolls never run out and machines never have to stop.
- The splicer solutions reduce the need for operator intervention and thereby minimize the risk of errors.
- With no manual intervention and thus a minimized risk of errors, operating costs are reduced.
- Automatic splicing maximizes uptime, improves profitability, and increases process reliability.
- Buffer and sensor control ensure smooth label web guidance and stable operation.
- Consistent processes enable high speeds while also reducing the workload on operating personnel.
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