Practical Guide to Building Sustainable Label Applicator Machines

In today’s manufacturing world, sustainability isn’t a choice, but rather a design challenge. Label applicator systems, though often overlooked, offer significant opportunities to reduce waste, energy use, and long-term operational impact.

This guide outlines key engineering principles and features that can help create more sustainable label applicator machines without compromising performance!

1. Design for Durability, Not Just Performance:

Use corrosion-resistant materials, self-lubricating bushings, and PTFE-coated sliding parts. Machines designed for 24/7 Indian factory conditions (dust, heat, humidity) not only last longer but reduce resource consumption from frequent replacements and service.

Self- Lubricating Bushings

How PTFE Coating Appears

2. Support Ultra-Thin Label Materials:

Standard label face stocks are often 60- 70 microns thick. Downgauging to 40- 50 microns significantly reduces plastic usage and increases the number of labels per roll, leading to fewer changeovers, lower shipping weight, and less waste.

PU Rubber Roller

Visual Representation of Micron Difference

To Support This:

• Use adaptive pressure systems (spring-mounted or pneumatically adjustable)

• Incorporate fine-tuned tension control

• Design wipe-down rollers with soft-touch materials (PU, silicone) to prevent tearing or misalignment

3. Make It Modular and Upgradeable

   Instead of designing monolithic systems, create modular machines where components like the control unit, sensor array, or label heads can be upgraded independently. This supports long-term use, easier tech adoption, and reduced scrappage.

   Further, design components that are easy to disassemble and recycle. Where possible, mark materials for recyclability. Consider setting up systems where major modules can be refurbished or bought back, extending machine life.

   
   

   

   
   

4. Use Energy-Efficient Motion Systems

   Switch from pneumatic to servo-driven systems wherever feasible. Servo motors with closed-loop control reduce idle movement, improve precision, and significantly cut power consumption  specially in high-speed production lines.

   

   
   
   
   

5. Minimize Label Waste Through Better Controls

   Engineering high-speed systems with real-time sensing (for label gap, product presence, and tension) prevents double-feeds, jams, or misalignments that waste both labels and product. Implement programmable batch settings to avoid overruns and ensure precise stop/start cycles.

   A Video Depiction of How A Gap Sensor Works

   
   

6. Ensure Compatibility with Eco-Conscious Packaging

Eco-friendly packaging (recycled bottles, biodegradable films, uneven glass) often behaves differently under load. Wrap systems should allow for:

• Adjustable pressure settings

• Non-marking contact surfaces

• Reduced mechanical stress to prevent damage

7. Go Digital, Go Paperless

   Include HMIs that store recipes, track faults, and show diagnostics in real-time. This eliminates the need for paper-based logs and improves decision-making speed. Ethernet/IP or IIoT-compatible controllers can enable remote monitoring and predictive maintenance.

   Basic Explanation of an HMI