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The solution to a tricky high speed, accurate labelling problem has been supplied by Sessions of York to Belgrave Graphics Ltd. in the form of custom built labelling equipment. The fully automatic Magnum 2000 flat-pack labelling system, selected after being seen at a packaging exhibition, is designed to apply double sided self adhesive fixing labels at one pass to the back of Christmas gift tags printed on a matrix in multiples of five tags per sheet. The labelling operation involves speeds of up to 10,000 sheets per hour and critical placement of the labels.

Belgrave Graphics Ltd. manufactures a wide range of greeting cards and tags. The company was looking for a complete stack-to-stack answer to the very demanding requirements of this application. Sessions was able to supply one of its Magnum systems using two Spectrum high-speed labelling units and associated peripheral equipment.

In addition to the labelling equipment, Sessions also supplied the double-sided labels to complete the system. Utilising the hot melt coater on its 10-colour Arsoma combination press, the company's Label Division was able to coat the adhesive onto the labels simultaneously with printing and die cutting. By utilising a combination of hot melt and proprietary one sided material Sessions was able to offer a peel here non adhesive finger edge whilst reducing the overall cost of the labels.

To enable application of the five labels at a single pass the Spectrum labellers were mounted in tandem. A significant level of control at high speed was achieved by incorporating Sessions' Spitfire intermittent feeder, a dedicated vacuum conveyor and an out-feed catchment hopper. Having an adjustable speed of up to 50 metres/mm, the two Spectrum labellers were encoder linked to enable accurate speed synchronisation. The Spitfire feeder also makes setting up and product changeover both quick and easy with just one simple adjustment.

Owing to the high speeds and level of accuracy required, Sessions also supplied a software program, written specially for this application, to provide complete control of the positioning of each label within the matrix surface area. In order to save space, the system's footprint was minimised by installing the Spectrum labellers in piggyback formation and feeding both lines of labels through a common applicator beak.

The fully automatic Magnum system can handle virtually any type of self-adhesive label including multi-layer labels and booklets for high-speed printing and in-register application to any flat pack. The modular system can be configured using a variety of elements to match precisely the requirements of individual applications. It can be installed in-line or as a stand-alone unit and can be specified to operate over a variety of speeds on short to medium runs of a wide range of flat objects and packs such as polythene bags, paper and cards.

The user-friendly Spectrum labeller, which is designed for high-speed application of self-adhesive labels onto virtually any type of product features a system of integrated electronics which offer an extensive range of advanced features. The integrated electronics provide a master/slave function that can also enable two machines to work in alternating relay mode to eliminate downtime during label reel changes.