DLP-2100

Recently, we deployed our first DLP-2100 Digital Label Press from Afinia:

DLP-2100 Label Press

Watch the DLP-2100 press run here:

And learn more about the DLP-2100 from Afinia’s website:

Tony Molina, our graphic artist, participated in the deployment.  According to Tony, “The DLP-2100 is fast, compact, precise and a workhorse of a machine”. At first glance, he thought setting up the DLP-2100 seemed very daunting and complicated.  To make it easy, Afinia placed a digital diagram on the DLP-2100 press control panel that shows you the paper path you need to follow, so loading up the paper throughout from beginning to end seems relatively easy to accomplish. After watching Paul Lueders from Afinia finish the training session for the day, Tony’s final thought was... “all these moving parts feel very synchronized and the entire unit runs very smooth. The finished die-cut labels look fantastic. Wow! this machine is very impressive!”

DLP-2100 Rotary Press

When asked, what is the most difficult aspect of operating the DLP-2100 press, Tony said, “Learning and navigating through all the functions on both the L901 printer and the Press touchscreen panels.

You can operate them simultaneously or independently from each other.”

DLP-2100 Die Cut Label

When ask about the main benefits of the DLP-2100, Mike Atkins, National Sales Manager for Afinia Label, said “The DLP-2100 has many benefits. It features flexibility, speed, print quality, and more. I believe the best benefit, during the current business climate, is controlling the supply chain for your packaging. We have seen higher pricing and slower delivery from label manufacturers in the United States. And companies who were outsourcing printed labels from Asia are now finding it very difficult to get them in a timely and cost-effective manner. I think we will see a trend of companies bringing labelling in house as part of a larger strategy that lessens reliance on the uncertainty around the supply chains.”

Watch Mike in a video on the DLP-2100 here:

To make sure a deployment of the DLP-2100 works well, Mike says, “I find companies who successfully implement an in-house digital press focus first on training. Identify a project lead to operate the press, and give them some ownership of the project. Also, it is extremely important to train at least 1 if not 2 back-up operators. If digital label printing is going to become a mission critical part of your manufacturing, make sure to have a few people able to operate and maintain the press."

I asked Mike, what skills are important to operate a DLP-2100 press?  He said, “First, have access to a graphic designer. This is not just for designing great looking labels, but also for setting up the artwork to match the die, making minor tweaks in the designs, and creating the artwork required for ordering new, custom dies. Finding an operator with some press experience is a plus, though not entirely necessary. When selecting an operator, find someone who has well developed mechanical skills, with the eye for detail to maintain the press routinely. Keeping the press clean and free from adhesive build up or dust will help ensure maximum up-time.”

After running the press, the most important question I asked Mike; what companies should consider purchasing a DLP-2100.  Mike said, “A private label manufacturer is our main customer for the DLP-2100. Because the DLP-2100 uses dies to cut labels at high speed, every size will require a custom made die. Dies are not expensive, around $150-$200 on average. But they do take about a week to order. Contract manufacturers, and white label packagers typically use a small range of containers, and therefore, do not require a large number of dies.  The DLP2100 is extremely fast, easily capable of producing tens of thousands of labels per hour.”

If you produce a large number of a limited size of labels, you should consider the DLP-2100.  You’ll save money on labels, improve your supply chain and give manufacturing great flexibility to meet your customer’s demand.

Contact us to learn more about the DLP-2100 and how we can help with the deployment of this large volume digital press.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com 

 

PAC5-2X

Last year, our parent company, General Data (GDC) introduced the PAC5 label applicator for the C6000P printer:

PAC5 Color Label Applicator

In fact, I wrote about it (at the very start of the pandemic):

https://colorlabelsondemand.blogspot.com/2020/03/pct5-color-label-printer-applicator.html 

And for this year, GDC has updated this unique device and produced a new video:

According to John Robert, Automation Engineer for General Data, “we improved the overall design of the PAC5 label applicator.  It runs faster by starting the printing of the label sooner, we changed the timing and tension on the linear, so applying labels is quicker, enables more applications to various shapes and sizes.  Plus we placed a new cover and bigger logo on the machine.”

After watching the video, I was interested in the ability to apply labels to round containers using a tamp applicator.  According to John, “as long as the containers/bottles are pliable (squishy), the PAC5 can apply labels in the very precise location.  You may need to finish the label application by wiping the edges by hand, but the label will be placed accurately.”

When purchasing the PAC5, a C6000P printer needs to be purchased also.

C6000P

Purchase theC6000P here:

and don’t forget Spare in the Air (SITA):

With SITA, Epson sends a replacement printer out overnight if the printer needs repair.  This extended warranty is important when label printing is a critical path to your production.

When ask who should purchase the PAC5 Label Applicator, John says, “Any operation that prints one label and then applies the label should be using the PAC5 applicator.  In these situations, the label may contain serialized information such as a unique ID, sequence numbers, lot codes, time stamps, line number.  Or any short line manufacturers to produce and label batches of 50 or 100 items.  The PAC5 makes sure the labels are applied precisely and with the correct data.  From my past experience, Pharmaceutical, food, GHS and cannabis companies would seem to benefit from the use of this type of machinery.”

Purchase the PACT5 label applicator here:

From my perspective, what John has created is unique and has not been an easy task.  Print one, apply one color label applicator has been wanted by manufacturers for many years.  Now you can add this capability to your manufacturing process saving labor, reducing potential errors and improving the aesthetics of your products.  Contact Color Label Solutions to learn more about moving to printing and applying color labels on-demand.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com 

Kiaro Vs C7500

The Kiaro (and the newer QL-120) from Quick Label Systems has been one of the largest selling color label printers on the market.

Kiaro Color Label Printer

I know this printer mostly from my work with current customers that have switch away from the Kiaro/QL-120.  Often, I speak with prospects who had decided to replace their Kiaro with a C7500G (and now even a C6000/C6500).  Based on these discussions, I decided to try to describe the important differences between the Kiaro (and the other options sold under different names) and the C7500G/C6500. 

Before starting, please know that the Kiaro is the exact same printer as the Swiftcolor SCL 4000 D/P sold by Kanematsu.  

Swiftcolor SCL 4000D

Many years ago I wrote about the Swiftcolor printer in this post.

Kanematsu sells the printer to AstroNova/Quick Label Systems under an OEM agreement.  Up until recently, Kanematsu was the distributor for Canon outside of Japan for this label printer.  In January, 2018 at CES, Canon announced the launch of these printers in North America:

https://www.usa.canon.com/internet/portal/us/home/products/details/production-printing/inkjet-label-printers/lx-d5500

Canon LX-D5500

Now you have access to purchase the same printer from three different companies. In this post, I’ll use the brand name, Kiaro to represent all of the options.  And please remember; we don’t sell the Kiaro printer any longer.  It’s just too difficult to keep them running.  But more about care and maintenance of these color label printers later.

Looking at the Kiaro (QL-120), I see 4 unique benefits vs the C7500G. First, the Kiaro offers up to 1200 x 1200 dpi print resolution; much higher than the C7500G with 1,200 x 600 resolution. I’ve seen great print quality from the Kiaro printer.

Second, the Kiaro comes in either dye or pigment-based inks.  Die ink are much more vibrant; but are not water resistant or water proof.  The ink will come off labels easily.  Pigment inks are very durable; but are not as vibrant in color as the dye Kiaro models.  But the choice is good to have depending on your requirements.

Third, the minimum width of a 4” version of the Kiaro printer is 25 mm or .984”; which is narrower than the C7500G at 2”.  And the minimum length of a label is 6 mm or .236”; much shorter than the 1” minimum of the C7500G.  Narrow widths and shorter lengths make the Kiaro printer fit many more applications.

Fourth, the Kiaro offers an optional cutter.  For tag application in apparel or greenhouse, this cutter is a unique capability.  At the 2017 WestPack, I saw the Swiftcolor printer with a cutter in action.  Read about the cutter for tags in this post.

Although the Kiaro has other features, I don’t see them as unique or valuable in the comparison with the C7500G.

As for the negatives, I see 3 with the Kiaro printer.  The first and largest is the 4 consumable print heads.  As each printhead may cost up to $750, it is expensive to replace this consumable item.  As I understand, the costs are $2500 to replace all 4 print heads at once.

How long one of the four printheads last depends on the material and percentage coverage of the labels printed.  Many years ago, I requested from SwiftColor an ink cost and printhead estimate on this 4 x 3” label:

SwiftColor Example Art

And they sent me this estimate:

SwiftColor Ink/Printhead Estimate

Although my request was concerning ink cost, the printhead life was more interesting to me.  At 161,186 4” x 3 labels, the printhead cost per label was 483,000 inches and added $0.0046/label; almost ½ of a penny per label for just the black printhead.  If you add up the cost of all 4 printhead, the cost per label was $0.013 just for printheads (assuming $750/printhead).  At the time, I was told the black line around the label reduced the black printhead life.  In this example, the printhead cost was almost as much as the ink cost/label. (Remember; these costs were from many years ago.  The printhead price has changed).

In addition to the cost of the consumable printhead, installation of one of the four printheads is not so easy.  To replace the printhead, you need to drain the ink, disassemble the printer and remove 1 of 4 printheads, reassemble the printer and then recharge the ink.  In this video, Quick Label Systems assumes you want to change all 4 printheads at one time. 

However, most people will want to change only the affected printhead.  You’ll need to remove and replace the printhead from the array.  Changing printheads requires an operator with mechanical skills, time and patience to do the job correctly.  With the C7500G, the printheads are permanent and not a consumable item.

In addition to the consumable printheads, the Kiaro printer has other consumable items.  The second negative is the time and money required to change these items.  The Kiaro has a “Blade Cleaner”, “Purge Unit”, and “Maintenance Cartridge” which are considered consumable items.  In addition, the printer has parts that need to be replaced as required such as the “Transport Unit”. To replace many of these items, draining the ink and special tools are required.  The time and money required to change these items seems onerous to me.  The C7500G has a “Maintenance Kit” that takes seconds to change and costs $31.  I tell customers that they’ll need approximately 3 of these kits per year with heavy use.   

Lastly, the Kiaro printer seems to require much more work and maintenance to keep these printers operating.  By the accounts of formers users now customers, the Kiaro printers have issues with streaks and require lots of repair.  Although having C7500G printers that required repair, we’ve found these printers durable and reliable.  Plus they are much easier to operate.  For most customers, operators of the C7500G must just press “Print”.

And the new C6000/C6500 seem to have less risk of streaks; learn more here.

And the C6000 costs a lot less. 

Although the Kiaro can print great looking images, and produce very small and short labels, the requirements to keep these printers running appear to be too difficult for most users.  In this regard, the C6000/C7500G is much easier to use and reliable while producing great looking labels.

As for another comparison, check out a previous post, the LX2000 vs the C7500, here.

Another point to consider: the Kiaro printer comes in an 8” version as well.  However, the 8” version is two 4” version stitched together.  No only does this printer have 8 printheads to replace, but also has had issues with the stitching of the heads.  Because of this issue, I believe Quick Label Systems launched their Memjet printer, the QL800 and purchased Trojan line of printers.  Now just get a C6500 printer for less money and better/more reliable printing.

I hope this comparison helps with your analysis of the available printers for on-demand color labels. Contact us if we can help with your color label printer requirements.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com