PkgT 1201 – Module 9

Coding and Inline Printing Systems

CODING

Most packages, especially of consumer goods, require variable information in addition to the fixed information
that is included on every label, bag, carton or other package. The fixed information will usually be an aesthetically
designed combination of colors, graphics, text and logos.

“Code” is the variable information printed to containers. Typically, it is a single color in a simple alpha-numeric font
and will sometimes include a bar code. It is applied to the containers by “coders” for the purposes of this module.
The code may only vary between lots. One example is a “Sell by” or “Expiration” date or a manufacturing lot
number. Sometimes the code will vary within the lot such as a shift code or time stamp. In still other cases, it will
vary with every product, such as a sequential or serial number. Some codes will contain all three types of variation.

“Inline printing” is a term that is semi-synonymous with coding. Coding that is applied synchronously to the
package or component at the point of processing such as to a label as it is being applied, to a bottle as it exits the
capper or to a carton as it is being erected, filled and closed in the cartoner is inline coding.

Components of a code

Lot numbering could be sequential or serial. A

sequential number is a series of numbers that follow a
predictable pattern such as 1, 2, 3, 4, 5 or 5, 10, 15, 20,
or even 13, 26, 39, 52. Serial is one that does not follow
a predictable pattern. It may be assigned randomly and
recorded to assure that it is not reused.
 PkgT 1201 – Module 9
Coding and Inline Printing Systems
Factors considered in selecting a coding technology

 The type of code to be printed. If the code is to be changed infrequently, such as lot-to-lot, a hot stamp
imprinter may be a good choice. If higher speeds, more complex number schemes or time stamping are
required, it will be necessary to consider an inkjet, laser or other system that can change on the fly.

Laser coding

Inkjet coding

Hot stamp coding

 If line changeovers are frequent, it may be desirable to select a programmable coder, this will reduce the
amount of downtime between lots.
 Product motion, continuous or intermittent, is another consideration. Inkjets require the product to be
moving during coding. Stamping coders, require the product to be stationary. Some can be set up to work
either way.
 Speed and how it is measured is always a consideration. Some coders are rated by the number of codes
they can produce per minute, others by linear speed.
 The coding technology must be matched to the material. Lasers will work well on printed labels or cartons
and on some types of plastics (such as PET). The ink applied by an inkjet printer may not stick well to the
varnish applied as a top coat on many label, provide an unvarnished window or “knockout” for proper
coding.

Unvarnished area for inkjet coding

If a laser is to be used, it may be necessary to add a color block.

Color block for the laser code.
Code here As output of laser code is
colorless, block has to be a
Printed carton in white
contrast color. If area to be
background
printed is already a contrast
color, no need for a color block.

 Aesthetics must always be considered. This is especially true when the code is on the primary package.
Codes must be legible to the end user but they must not detract from the over graphics of the package
 PkgT 1201 – Module 9
Coding and Inline Printing Systems
 Packaging line environments will affect the choice. If the coding is to be done in a flammable area, it may
be best to choose a fully pneumatic rubber stamp type system. This can eliminate the need for expensive
explosion-proof systems.
 There are two costs for a coding system. First is the cost of purchase. Then there is the cost of operation.
Some systems, such as inkjets, can be purchased relatively cheaply. The low purchase price is offset by the
purchase of ink and solvents, as well as by maintenance costs. The purchase price of a laser may be high in
comparison but is offset by the lack of consumable supplies and the low maintenance requirement.

Two types of coding

Coding technologies can be divided broadly into contact and non-contact. As the name implies, in contact coding
technologies, the coder and material must come into direct contact with each other.

Contact

Roller coder
The simplest coder in common use. These are often used for coding corrugated cases at relatively low speeds. They
are also used for other large, slow-moving products such as pails and drums or even gallon bottles.

Ink roller
Printing wheel with rubber plate
Spring loaded
mounting bracket

https://www.youtube.com/watch?v=Bb6XnrejrwY

Its rubber plate could be individual rubber characters (right) fitted to the wheel to form the code, or in a form of a
rubber mat specifically created for the run which has the complete code in a single mat as shown on the left photo
mounted on the printing wheel.

Wet ink, however applied, always has the potential to be messy. The mess is outweighed by the low cost and
simplicity of the system. Absence of any power supply also makes this a good choice in a flammable or explosive
environment.

Rubber stamp
Rubber-stamp coders use similar technology to the roller coder but require intermittent motion of the product.
This is not used so much in automatic machine applications.

Hot stamp
Hot-stamp use individual type pieces but can also use pre-made plates to print the code. The mechanism is similar
to the rubber-stamp coders but the type or plate used for hot-stamp imprinters is metal and is mounted in a
heated, removable fixture called a “chase” or typeholder.
 PkgT 1201 – Module 9
Coding and Inline Printing Systems

Individual type pieces Chase or typeholder Hot stamp ribbon

Metal type is not flexible like rubber type so even small differences in the height alignment of the type will show
up in the printed code. Type should be purchased in matched sets and discarded when worn.

Once the type is configured, the chase is inserted into the printer and allowed to heat to a temperature of about
250 to 300 degrees F., depending on the material to be printed and ribbon to be used. The ink in a hot-stamp
imprinter is supplied as a plastic ribbon coated with a dry, heat-sensitive ink. Black ink is commonly used but other
colors are available.

Applies the pressure

on to the stamp
https://www.youtube.com/watch?v=fhDJsapARXs

To apply the code, there must be fair pressure between the stamp and the container to be printed. As the type is
metal, corrugated boards could deform in pressure so it is not advisable to be coded through hot stamping. Too
much pressure applied during coding will cause rapid wear on the characters and the backing plate. Their quality is
critical to ensure consistent legible code.

Debossing
Debossing is similar to hot stamping but without the ribbon— the type is pressed into the front of the package,
leaving a physical impression—and usually without the heat. When plastic is to be debossed, the type may be
heated to assist it in deforming the plastic.

https://www.youtube.com/watch?v=4GL9H7VnIK0
 PkgT 1201 – Module 9
Coding and Inline Printing Systems
Debossing has several advantages. The most obvious is cost. As there is no ribbon, this cost is eliminated. It does
not print on the package, in most cases, it is applied on top of any graphic which is space saving. However, as it is
not printed, it could be not too visible which is disadvantageous in some applications.

Non-contact

Inkjet
Work by spraying ink from a printhead onto the package to form a legible code. Common inks are solvent (usually
methyl ethyl ketone or MEK), alcohol or water based. Some inkjet printers use a solid resin or wax, which is melted
immediately before being sprayed onto the package. Ultraviolet (UV) and other quasi-invisible inks can be used to
print on top of existing graphics. They are invisible in normal light but readable under an ultraviolet light. Special
UV inks are formulated to be visible only under a particular UV wavelength. This can be useful as an anti-
counterfeiting technique.

Ink is sprayed through the nozzle according to a set matrix. Example matrix of 7 high x 5 wide will let you print
within the 7 x 5 dot positions.

The further away from the nozzle the product is, the more the dots will separate vertically and the taller the code
will be. This is noticeable in round bottles where codes on the sides will be farther from the center of the nozzle.
This difference in distance will result in the code being taller at the ends than at the center giving a “bowtie” effect.

Bowtie effect

Could also be caused by

some clogged nozzles

Speed is rated in linear speed. The speed it can print has to be synchronized with the conveyor speed. In coding, a
sensor is mounted before the nozzle head of the inkjet coder. This will provide feedback on the coder to discharge
ink. (https://www.youtube.com/watch?v=hQXyqKAnJUo)
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Coding and Inline Printing Systems
Laser
Lasers used in package coding may be thought of as “un-printers.” They work on printed materials such as labels or
cartons by using an intense beam of light to remove the existing ink from the package. The energy of the laser
beam directed onto the package is absorbed by the ink. The ink heats and vaporizes exposing the substrate
underneath. Generally, lasers will require a colored area for visible codes (color block as discussed earlier above).

When using lasers on printed materials, it is important than an unvarnished area be provided for the laser to mark
into. The laser will heat and vaporize the ink under the varnish. The varnish may not allow the vaporized ink to
escape and bubbling of the varnish can occur. There are some varnishes formulated especially for laser coding but
if these are not used, it is important to leave an uncoated area for coding.

Metal containers and caps generally respond well to lasers. The laser removes the surface coating exposing the
primer coat below. Caution must be used to avoid removing the primer coat. If bare metal is exposed, it may be a
point for corrosion. Metal must always be coated to be able to be marked with lasers.

Laser coding on carton and metal can

Lasers work well with molded or tubing glass bottles and vials. The laser causes a microfracturing of the glass
surface to give an etched appearance. Unlike some ink codes, laser codes have the advantage of being in, rather
than on, the glass surface and cannot be removed. Not all glass responds equally well to lasers, so it is always
important to have samples made on the actual glass to be used before making any final decision on the coding
equipment to be used.

Laser coding on glass

 PkgT 1201 – Module 9
Coding and Inline Printing Systems
Not all plastics can be coded with lasers. Most polyethylenes, unless they have an additive, are transparent to the
CO2 lasers commonly used in packaging. As they are transparent, light beam will pass through the material, not
being able to transfer the energy on the surface to code. Some polypropylenes will code nicely, others will either
code poorly or not at all. PVC is an excellent substrate for laser. As the laser energy is absorbed, the surface of the
PVC turns amber. PET codes well with lasers. The beam etches sharp characters in the bottle but with no color
change.

Laser coding vs inkjet coding on PET bottle

Lasers, like any other industrial equipment, can pose a safety hazard from the intense light beam and the high
voltage used inside. It is critical that they be appropriately guarded and operated and maintained only by trained
personnel.

There are three types of laser coders. Pulse, dot matrix, and scribing.

Pulse lasers
Pulse lasers generate a single pulse of laser energy for each individual code. An advantage of the pulse laser stems
from its optical nature. This allows a lens to reduce the code to an almost microscopic size while still retaining the
full sharpness and legibility of the characters. This can be useful if it is desired to apply a hidden code as an anti-
counterfeiting or anti-diversionary measure. (https://www.youtube.com/watch?v=MLO9eW41qg0)

Stencil mask
which should
be premade The lens that
for the code concentrates
made of the laser onto
beryllium- the substrate
copper alloy
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Coding and Inline Printing Systems
From above schematic diagram, the use of stencil mask limits the application of pulse lasers. It limits the variety of
fonts or images that are generally practical.

Dot matrix lasers

Dot matrix lasers print codes as a pattern of discrete dots and are similar to inkjet printers in this respect. The
matrix may be as small as 5 dots high x 3 dots wide. The more dots used to form the characters, the more fully
formed and legible they will be. https://www.youtube.com/watch?v=oo8KBoP_kvQ

Scribing lasers
Older scribing systems were used for marking applications but were not generally suited to packaging
applications due to required speeds and the need for the product to be stationary during coding.
Current scribing laser technology allows coding on the fly, at speeds to several hundred codes per
minute depending on the package and the information to be printed.

Mirrors that concentrate the

laser onto the substrate is
driven by a motor to move
according to the character
printed, two mirrors moving
on the x and y axes

https://www.youtube.com/watch?v=p72tK4WtzFY

INLINE PRINTING

Inline printing begins with blank, or generic, material and prints it just before or as it is applied to the product.
Often the materials are blank but sometimes they are pre-printed with generic information applicable to all
products, such as company logo. The balance of the information is printed on the packaging line as the material is
used.

Inline printing is done to offset the stringent inventory requirements of pre-printed labels as well the longer lead
time requirement. Printing labels in smaller quantities would also be too costly hence leaning to inline printing.
 PkgT 1201 – Module 9
Coding and Inline Printing Systems
Inline printing overlaps with coding discussed so far. There is no bright line distinction between the terms and they
are sometimes used interchangeably. The main difference is the quantity of information to be printed and the
required quality of the printing.

Thermal Transfer
Thermal transfer is the most common technology used in inline printing. Thermal transfer printers use an ink
ribbon. It melts the ink from the ribbon, depositing it on the substrate, such as a label. Labels are supplied in
continuous form, either on a roll or fan-folded.

Blank label roll driven by a motor

Ink ribbon
Rewound used ink ribbon

Printhead which applies pressure and

heat on the ink ribbon and the
substrate which is triggered by a
software.

https://www.youtube.com/watch?v=Nd9Dgd0tVCU https://www.youtube.com/watch?v=f4aFidJa37E

The width of the label roll and the ink ribbon should be matched. Above illustration is a tabletop standalone
machine but this could be inline, integrated into the labeling machine. As with any systems utilizing rolls, tension is
important which is controlled by dancer bars. Most thermal transfer printers will print only a single color and that
color is usually black although other colored ribbons are available.