Be Your Own Best Customer

Thermal-transfer printed bar codes are a quality control and workflow enhancement tool for a converter's own operations.

By Ann Marie Cook, Weber Marking Systems

In an average day, a pressure-sensitive label converter will produce countless rolls of pressure-sensitive labels for its customers. The labels may be attractive, process color labels for prime applications; or they may be custom or stock product identification or shipping labels for secondary applications.

The label designs and applications will vary, but a large percentage of these unique products will have one element in common: bar codes.

Though converters manufacture labels for bar coding every day, some still don't see how implementing their own internal bar code labeling systems could streamline their production costs and increase profitability.

Label converting is a manufacturing process. Converters share production issues and goals with manufacturers in other industries. We all want to produce the highest quality products using the most cost-efficient methods available. To accomplish this, numerous manufacturers have incorporated bar codes into many of their production tasks using in-house bar code labeling systems with thermal-transfer label printers, data capture equipment, custom software and pressure-sensitive bar code labels.

Advancements in on-site thermal-transfer labeling system technologies are highlighting opportunities for bar coding to be used to complement existing manufacturing capabilities in today's more progressive label converting operations.

While there are several printing technologies available for pressure-sensitive bar code labeling, thermal-transfer printers are extremely versatile and offer consistently reliable results for higher-volume industrial applications.

Industrial thermal-transfer printer models range from economical to high-performance, at a cost of $1,000 to $9,000. Wide- or narrow-web capacities accommodate a variety of label sizes, with widths from .79˝ to 7.2˝ and lengths from 1Ú4˝ to 20˝. Standard models usually offer 203 dot-per-inch (dpi) resolution, with 300 dpi resolution available for higher-density applications. In both cases, thermal-transfer technology, when used with the appropriate printer ribbon and thermal-transfer label material (see Moving Beyond Black in this issue), produces crisp, smudge-resistant text, graphics and logos, along with in-spec, single- and two-dimensional bar codes.

Additionally, printer systems manufacturers are continuously feeding the marketplace with more user-friendly models. Advanced modular designs require less set-up time, plus they incorporate or offer options that enable printers' capabilities to easily—and relatively inexpensively—expand as applications grow and change. These devices include cutters, rewinders, peel bars and memory expansion options.

Most printers also offer powerful processors to produce labels at efficient throughput rates, either on demand or in large runs. Many operate in Windows environments that, when used with a compatible labeling software package, encourage easy label formatting and efficient networking systems.

Finally, today's integrated, on-site labeling systems would not be complete without bar code laser scanners to collect, manipulate and transfer bar-coded data within seconds.

Streamlining Operations

Label converters could potentially be their own best label reference, as bar coding opportunities exist in all facets of a manufacturing environment, from the receipt of raw materials to the shipping of finished goods, plus everything in between.

On Receiving Docks

As large mill rolls, slit rolls, finished rolls and other raw materials are received, a bar code labeling system would enable data on the new material to reach several people at the same time.

Using a thermal-transfer printer, operators could print bar coded identification labels for incoming raw materials as they are being entered into inventory. Operators then scan each bar-coded roll with a bar code laser scanner and upload that data directly into a PC or central computer system, which would immediately update inventory records.

Using this method, purchasing staff could verify orders; production operators would know what and how much material is available; and, quality assurance technicians could more easily inspect incoming material.

Inventory Management

Using bar codes to manage inventory can not only reduce downtime, but it also can lead to a more accurate and profitable production facility.

For example, larger converting operations may have warehouse facilities that require numerous storage bays or shelves. In this scenario, bar code labels can be printed and applied to stored raw materials or finished goods, as well as to each shelf or bay. With a bar code on the product corresponding to a particular bar-coded location, anyone looking for specific materials would be able to find them more easily and efficiently.

Bar codes also are useful in tracking unused material. New labels can be printed and re-applied to scrap material, which can then be returned to inventory for later use. The obvious benefit is a reduction in waste.

Work in Process

In label converting environments, work in process involves the raw materials—such as substrates and adhesives—as well as all the tools used to produce the final pressure-sensitive product, including dies and inks.

Bar code labels on a collection of dies could provide valuable information on the life and the maintenance schedule of each die. Bar code labels on ink containers could improve the tracking of mixes, especially when large volumes are blended and stored for repeat jobs or customers.

Product Identification and Package Decoration

Like other manufacturers, label converters need to comply with their customers' labeling demands. More often today, customers are specifying unique bar code identification labels on their product shipments, and with the on-demand printing capabilities of thermal-transfer printers, a manufacturer can meet each customer's needs with virtually no label waste or downtime.

On-site label printing systems also afford converters the opportunity and capability to create labels that do more than just deliver bar-coded information. Product identification labels may carry their company logo or other attractive graphics to enhance their image. Special marketing efforts also can be executed on decorative package labels.

On Shipping Docks

Eventually, all products make it to the shipping dock where thermal-transfer printers can, at that point, once again, be very useful. Virtually all package delivery systems—whether the U.S. Post Office, FedEx or UPS—rely on bar codes to track shipments. UPS has recently incorporated two-dimensional bar codes into their tracking system. With the appropriate database system and labeling software, bar code shipping labels could be formatted and printed directly from existing customer data files.

In-house Service Bureaus

In addition to streamlining internal operations, thermal-transfer printers can play a special role in a label converter's product offering. Many converters offer their customers in-house service bureau capabilities, where the converters will manufacture their customers' labels and then imprint their variable information using stand-alone systems.

Thermal-transfer printers are a natural selection for service bureau operations due to their high-resolution technology and rapid throughput.

This is a smart service to offer customers whose own operations do not benefit from an on-site system, such as those with very low-volume runs, extremely high-volume runs or operations requiring finished labels to be sent to multiple locations. Some service bureaus offer short-runs using multi-color-capable thermal-transfer printers.

Tangible Benefits

The benefits bar codes bring to a manufacturing environment are very real. In addition to using bar codes to track inventory and comply with customer requirements, converters can accurately determine setup and press run times to better track production costs. They also can reduce errors and simplify procedures by replacing manual data entry with bar code laser scanners. The ability to track finished products back to raw material vendors for quality accountability is inherent with these systems.

In an industry where the cost of a final product is sometimes counted in fractions of cents, bar codes can make a business more cost-effective and, in turn, more profitable.

To get started in bar coding, converters need to get in touch with a qualified vendor that will be able to help them find the right labeling system to tie together every aspect of their business. Because of the complementary product line, many converters may already have relationships with vendors that provide such products and services.

Look to them first, and then look to yourself for the best thermal-transfer pressure-sensitive labels you can buy.