One for all, all for one

An Ask the Expert feature with Thorsten Schnatz of KBA Metronic

The practical requirement

To allow small and medium runs to be handled quickly and efficiently, folding boxes in a variety of sizes were to be separated, printed, labeled and checked. Where possible, the solution for all these tasks was to be provided by one supplier. “The precision and reliability of the inkjet printer are of critical importance for the finishing process and the entire quality assurance procedure: the codes on the boxes must be absolutely identifiable in the optical inspection,” says Christian Riediger, the engineer in charge of the project. This is where the continuous inkjet technology of Germany-based KBA-Metronic AG came into its own: the alphaJET C printed all the necessary pharmaceutical and data matrix codes in top quality, proven by a variety of inspection systems.

“Another challenge to the flexibility of the system engineering are the folding boxes with automatic folding bases which have to be handled in a wide variety of sizes,” adds Christian Riedinger. Here too, KBA-Metronic was able to hit the mark, with her UDA 150-S separating line.

The complete solution

KBA-Metronic AG designed an all-in-one solution for KVP. This solution is based on the UDA 150-S, which allows the folding boxes to be separated in an infinitely adjustable range from 80 x 40 mm up to 600 x 550 mm and precisely be led to the various labeling systems. It all starts with an alphaJET C inkjet printer with two print heads that codes and prints the folding boxes precisely both, portrait and landscape. The alphaJET C’s unique vertical resolution of 48 dots is particularly suitable for the encryption of data with 2-D codes.

The inkjet printer receives printing data such as the 2D code, GTIN no., MHD and batch number from a production line computer and transmits this information to a downstream camera with which the unit is in constant two-way communication. The electronic control system, crosschecks the printed data for content and quality against the data received and reports a fault in the event of errors or discrepancies at any time. In addition, faulty data is fed back to the production line computer. Thus, no data is lost.

The ttPRINT 53-i, an intermittently operating thermal transfer printer was integrated into the UDA to meet the special font requirements of the Asian and Arabic markets. S harp print quality at a resolution of 300 dpi is achieved at speeds of up to 800 mm/s (continuous mode). The ttPRINT too was linked with a camera system for reliable and efficient data-check.

As an additional safety feature, the UDA is equipped with a double-layer control to prevent unprinted copies from getting into the packaging process should folding boxes become jammed or glued together. This ensures optimum production reliability from the start to the end of the labeling process.

KVP is now operating with 18 alphaJET C printers, 4 ttPRINT printers and 1 UDA system – and the trend is upward. Implementation of the KBA-Metronic technology enables KVP to achieve almost just-in-time manufacturing, delivering significant savings in stock management and planning. The solvent recovery facility of the alphaJET C units also saves KVP a not inconsiderable quantity of solvent. Not only is this good news when it comes to the bottom line, but this recovery system also means that the emissions produced in the processes are kept remarkably low. The ttPRINT is similarly equipped with an automatic film-saving facility that sets image directly to image, avoiding costly voids in the thermal film. “It is our job to meet the international principles of good manufacturing practice for medicinal products, the requirements of the Food and Drug Administration (FDA) and the high quality standards of Bayer HealthCare AG. By being optimized to our own particular needs, the system solution from KBA-Metronic is playing its part in ensuring that we can meet these high requirements,” Riediger concludes.

Thorsten Schnatz is Director of Sales & Marketing (Coding & Marking Division) at KBA-Metronic. He studied Economies at the University Würzburg, where he awarded the academic degree of a Diplom-Kaufmann. He started his career at KBA-Metronic in 1998 and since 2004 has been responsible for International Sales and Marketing.