Preroll Label Applicator

“From label design to fully applied labels, the cannabis market is a great place to deploy a print and apply solution.  The Epson C6000A printer and the LabelMill LM1005 combination is an affordable way for cannabis manufacturers to print and apply labels to their packages”, says Chris Wachter of LabelMill.

Preroll Label Applicator

LabelMill has been producing custom labeling solutions for 30+ years. From Concept to Final Product, their Modular Labeling Systems are Quick to Deliver - Easy to Service – Easy to Use; producing more uptime for production lines, reducing the cost of spare parts and making employee training easier.

I’ve written about LabelMill in the past; focusing on their unique tube label applicator.

LabelMill 1005 For Prerolls

But now, we’re selling a print and apply labeling system featuring the LM1005 for preroll tubes in cannabis.  Watch the C6000A printer along with the LM1005 apply labels to preroll tubes.

I’ve found this print and apply system works great for preroll tubes.  According to Chris, “Preroll tubes are generally harder to apply labels given the typical tapered design and attached caps.  Placing a rectangle label on a taper tube can produce wrinkles in the label.  With the adjustable carriage on the LM1005, we can move the idle rollers up and down the shaft to make label placement precise.  This capability makes label application to preroll tubes easier to do.”

The standard carriage used on the LM1005 has two adjustable idle rollers.  These rollers can be locked on either side, which means that you can simply squeeze the rollers closer together on one end to help combat the taper of the tube.  If the taper is significant enough, we can also make custom rollers to match the taper of the tube, but adjusting the rollers is pretty uncommon.

LabelMill 1005 Idle Rollers

And less chance of a label wrinkle:

LabelMill 1005 Applied Label

In the video, you can see how the LM1005 applicator controls the production of the “loose-loop” of labels from the C6000A printer.  LabelMill design this print and apply solution with a cable for the applicator to send a signal on when to print more labels.  Controlling the label printing is very important in any print and apply system; but especially in loose-loop designed solutions.

Continuing, Chris says, “Prerolls tubes are a great application for print and apply systems.  With the high-quality design of cannabis labels along with the regulatory requirements for variable data, full color print and apply is a very efficient process as most cannabis manufacturers produce in batches.  Print on-demand and apply enables cannabis manufacturers to produce high quality designed labels with control of the unique data on each one.” 

LabelMill 1005 Applied Label To Preroll Tube

When asked, what advice would you have for users of the LabelMill print and apply system, Chris says, “Once set up properly, I recommend to our customers that they use High-Quality labels.  Make sure the labels are cut to the proper depth and don't use a too aggressive adhesive.  Good labels will reduce other costs like lost time and obsolete inventory which more than make up for any incremental expenses.

Print and apply of labels for preroll tubes make total sense to me. This solution is efficient and effective; increasing the productivity of your operation.  Plus, this system assures that every label is placed in the same place each time; improving the look and quality of your product.

If you make preroll or apply labels to any similar packaging, contact us to discuss how the C6000A and the LabelMill LM1005 print and apply system can work for you.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com 

L801 Printheads

After working with inkjet label printers for many years, one thing I’ve learned is that inkjet printer nozzles will occasionally plug.

L801 Printhead Streaks

I’ve written about preventing plugged nozzles on the C7500 printer:

And I’ve written about the costs of consumable printheads with the Kiaro printers:

But I’ve not written about what to do if a L801 printhead nozzle gets clogged; or how to prevent clogged nozzles on these printers. This post is designed to help L801 users (and users of any similar Memjet-based printers; Afinia L701, Afinia L901, VIP 650, VIP 700, etc.) prevent clogged nozzles as well as explain what to do if nozzles get plugged in the printhead.

Afinia L801 Label Printer

Keeping L801 Printhead Working

Label Rolls Packed In Plastic Bags

The number one recommendation to keep your L801 printer free of plugged nozzles is to keep your labels clean and in the original packaging as well as the room in which the printer sits clean.  Most of the material that plugs inkjet nozzles comes into the printer from the label media.  Generally, label rolls are shipped inside a plastic bag; and inside a box.  Keeping the rolls inside the bag limits the amount of dust that gathers on the roll; and prevents humidity from affecting the quality of the labels as well.  Keeping the room generally clean limits the dust in the printers as well.  Limiting the dust into and on the L801 printer is a good idea to keep your printhead working as long as possible.

Maintain Humidity

Number two; maintain sufficient humidity in the room with the L801 to prevent the nozzles from drying out.  Memjet, the maker of the L801 print engine recommends a minimum of 45% humidity.  This recommendations can make a big difference; especially in dry climates and during the winter months.

Number 3: Keep the L801 powered on if you use it within 6 days or less.  By keeping the printer on, the printer services the printhead; running ink into and through keeping the nozzles moist.  If the printer will not be in use for 7 or more days, remove the printhead following the directions and place it in the orange shipping cup in distilled water.

L801 Media Path

Number 4: Perform regular maintenance.  Clean the media path of paper dust by using a wet wipe or small vacuum.  Open the clamshell with the media ejected and clean the top and bottom of the paper path as much as once a day given your print volume. Be careful when cleaning the star roller platen; go with the rollers, not against them. And remove any adhesive that may build up inside the printer especially around the cutter.

Clean L801 Printhead

Number 5: Clean printhead manually occasionally.  Use distilled/deionized water on a lint free cloth to wipe the printhead after removing it from the printer. Never touch the nozzles with the moist cloth, however.  Wipe in one direction with the moist cloth. To remove the printhead, select Configuration, #3 Printhead, #2 Replace on the Control Panel.

L801 EWS

Number 6: Change Servicing Level.  Change the “Mid Job Servicing Interval” to Maximum in the toolbox under "Advanced Settings 1". This setting will allow the head to service more frequently which reduce the likelihood of plugged nozzles. (See table 2 in the L801 User Manual on page 36).

Number 7: Check Unused Nozzle Setting in the Embedded Web Server (EWS):  Check to make sure the setting "Keep unused nozzle wet" isn't disabled.  This setting is in the Advanced Settings 1. (See table 2 in the L801 User Manual on page 36).

The seven recommended steps/procedures will help keep your printhead functioning properly and as long as possible.  Do what you can/when you can to follow these recommendations as much as possible.

But sometimes, you can get a plugged nozzle even following these recommendations.  If you do find streaking from a plugged nozzles, follow these recommendations.

L801 Control Panel-Clean Printhead

First, complete a normal clean.  From the LED, select Configuration, #3 Printer 1, #1 Clean and then Normal.  Then complete another print to see if the streak remains. (See page #52 of the L801 User Manual).

Second, if the streak remains, complete an Extended Clean (follow above directions selecting “Extended”).

Third, if streak remains, clean the printhead following the directions above.  In addition, clean the PRINTHEAD Contacts.  Turn off the printer, and wipe the contacts in a vertical manner using a moist lint free cloth.

Fourth, if the streak remains, you may decide to complete an Extreme Cleaning.  However, select this option carefully as it consumes a lot of ink.  Generally, I recommend the next step in advance of the Extreme Cleaning option.

Soaking L801 Printhead

Fifth, soak the printhead overnight in distilled water.  Fill the orange cup in which the printhead ships with distilled water and then placed the printhead in the cup.  This step rehydrates the printhead. Plus, it’s a good way to store the printhead if the printer is not in use for more than 6 days.

Wipe L801 Printhead

Sixth, wipe nozzles as mentioned above using a moist, lint-free cloth. Wipe in one direction with no pressure.  This step may rehydrate the plugged nozzles.

If none of these steps fix plugged nozzles, then a new printhead is required.  As the printheads are a consumable item, replacements are required occasionally. 

In addition to plugged nozzles, I’ve learned one other item may cause streaking.  As the printhead ages, lines may appear approximately every ¾” along the web where the zones of the nozzles meet.  These lines are referred to as “Die Lines”.  These die lines are most noticeable in light, pastel or sky-blue colors. In addition, these die lines appear more on certain materials.  For example, gloss BOPP has very little “Dot Gain”; meaning the ink stays in a tight, small dot which makes the die line more likely to appear.  On other materials such as paper, the ink migrates or spreads out evenly; potentially overlapping the other dots, reducing the likelihood of a die line effect.  Over time, these die lines can’t be fixed and require a new printhead.  Following the recommends on maintaining the printhead will make this consumable item last as long as possible.

By following some or all of these recommendations, you can maintain your L801 (and related Memjet-based printers) printheads and potentially, unplugged nozzles.  Knowing and following these steps will reduce the possibility of streaks in your label printing.

Contact us if we can help with your L801 or any other label printer.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com 

Higher Speed C6000

In the spring of 2020, Epson started shipping the C6000 series printers.

C6000 Series Printers

I wrote about the launch of these new printers during the fall prior.

And my first, out of the box, experience. 

Overall, I’ve found these printers to print high quality labels and be affordable.  But slow.

Epson has now released a driver change that, according to them, increases the speed of larger, batch printing by at least 20%.  That’s significant.

Let me explain the procedure you should use to realize this increase in speed.  First, I recommend you update the firmware in the printer.  It may NOT be required for this speed increase; but it’s a good thing to do before making any other changes.  Get the latest firmware here:

C6000A

C6500A

(I didn’t include the “P” versions as we’ve sold primarily “A” printers with a cutter.)

Second, update the driver to version 1.4 (or later if available).  Get the driver on the same link as listed above.  Don’t worry about updating the driver with the previous version installed. (FYI: I had to restart my computer after updating the driver to get this feature to work).

Third, select “High Speed Batch Printing” in Driver Preferences on the Driver Utilities tab of the driver.

C6000 High-Speed Batch Setting

And then print a minimum batch size of 60 cm or about 24”.  The time to print 10, 4x3” matte poly labels printed using NORMAL setting and the high-speed setting not selected was about 30 seconds (~1”/second).  To print the same amount with the High-Speed Batch Label selected was 21 seconds (~1.4”/second); a reduction in time of 30%. (FYI: I should have measured the time before updating the driver and firmware to see if it was different).  

Watch me print 10 here in the High-Speed Batch Mode at the NORMAL setting.

Notice how the LED shows only 2 pages printed.  From 10 labels to only 2.

One point: on my first try, I got a skipped label.  It occurred between page 1 and 2 of the batch.

As I normally set up the page size of a label .03” wider and longer than the actual label, I figured this .03” extra times 10 labels caused the printer to skip the gap.  Changing the page size to exactly 3” tall, eliminated this missed label.  Therefore, you may not be able to use this feature when printing full-bleed labels.

Completing the same test using the MAX SPEED setting, it took 14.5 seconds (2.15”/second) to print 10, 4 x 3” matte poly labels.  With the High-Speed Batch Label Printing selected, it took only 9.5 seconds (3.29”/second) to print the 10, 4 x 3” matte poly labels.

How This Feature Works:

Normally, the C6000 series printers send 1 label image down to the printer at a time.  10 labels would be 10 images.  In the High-Speed Batch Label Printing mode, the printer creates a batch of 60 cm and send it down as 1 image; thus speeding up the print.  It seems like a creative way to speed up printing.

Epson does list some restrictions to make this work correctly.  For most, the NO CUT option could be an issue for some operations.

C6000 High-Speed Restrictions

To learn more about this setting, review page 112 in the Technical Reference manual.  Get the manuals on the same URL as the drivers; just select “MANUALS and WARRANTIES” tab on the Support page.

According to Dennis Moore, Epson Senior Technical Support Specialist, “This feature allows the printer to printed at the rated speed of 4.8 ips over a span of 24 inches and is especially advantageous when printing small labels.  I recall during the initial testing in March that multi-page labels could be printed using the high-speed batch setting as well.  Note that the page count on the printer panel is now defined in terms of 24” collections of labels instead of individual labels."

For many organizations, I believe this setting will help speed up their operation.  At a minimum, I encourage users of the C6000 series printer to test this new feature.  If you have issues using this new feature or help with your label printer in general, contact us so we can help.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com 

Loading The DLF

 Loading printed labels and laminate into the DLF220S looks easy; right?

DLF Media Path

For me, however, it’s not so easy.  That’s why I asked Tony Molina, our graphic artist to help me load the DLF220S.

In my post about Sierra Stickers; I asked our customer Derrick, “how long did it take to get comfortable using this label finisher?”  Derrick said “two weeks to really learn how to use this finisher”.  And Derrick is a professional printer.  You should add to this time if you don’t use it every day.

Frankly, I’ve avoided learning how to use the DLF as I’ll never use it every day.  This post is designed to share some insight into threading the DLF220S media path; and not to make you an expert.

Load Printed Labels/Laminate

First load the printed labels and laminate onto the spindles and tighten the label core holder.

Load Into Coupling Roller

Lock Coupling Roller

Second, insert the labels into the coupling rollers and lock the knob. Afinia suggests using the 2^nd hole from the left (which we didn’t do as shown by the picture above).

Attach the Laminate

Third, pull down the laminate with both hands, centering it onto the label media. And then tighten the laminate core holder. Make sure to adhere the laminate to enough of the paper area so as to not have it come apart when you first advance it through the coupling rollers.

Attach Laminate

Tony prefers to place the laminate onto the guide roller to help smooth and center the laminate, then supporting the paper from below against the guide roller to ensure easy alignment of the laminate to the roll of paper.

Advance Labels/Laminate

Fourth, use the manual button to advance the label and laminate. Be prepared for the noise of the laminate coming off the roll.

Under Damper/Into Rollers

Fifth, run the labels under the damper arm and up through the aluminum rollers. Adjust the edge guides to maintain the media straight.

Into Cutter

Align Edge

Sixth, lift the handle or latch on the rear of the plotter and push the media through the two pinch rollers. Align the media by having the edge of the media touch the edge of the silver sticker alignment points.

Push Thru Cutter

Seventh, move the pinch rollers to the media edges on both sides. You can move them manually as long as the handle or latch is up in the unlock position.

The entire surface of the pinch rollers needs to make contact with the media surface edge on both sides.

Close Lever

Eighth, close/lock the plotter by pressing down on the handle or latch securing the media.

Select #2

Ninth, select #2 on the plotter display. 

Tenth, I had to start the Graphtec cutter software.  Get the DLF latest software here: 

Open the DLF software, and then from within the DLF software open the PDF CUT FILE.  Measure the distance from the leading edge of a black mark to the leading edge of the next black mark on the printed media. You need to be as accurate as possible.

Enter Blackmark Distance

In the “DISTANCE BETWEEN BLACK-MARKS”, enter the distance in mm.

Advance Blackmark

Use the forward media single arrow button to slowly advance the blackmark into the camera square shown in the software. The double arrow button advances the media much faster but is harder to control.  You want to align the black mark in the center of the blue box as much as possible.

Prior to running a CUT TEST, check the plotter knife using the loop that came with the DLF unit.

Check Plotter Knife

The blade should be set to hit the 3^rd mark from the bottom seen in the loop.

If the blade cuts the liner, change the CUTTING FORCE on the DLF software. (You may need to remove the die-cut label to confirm the cut depth. In this training session, we had to change the cut force from 11 to 9. You can continue to do the cut test until the correct depth is found.)

Cut Too Deep

NOTE: At this point, it is very important to remember that before you run a CUT TEST, the Media Tension Control needs to be activated and set to AUTO.   Then select CUT TEST.

Activate Media Tension

Eleventh, something that we didn’t do in my training was to correct the offset in the software to make sure the label is aligned with the die-cut.  You can move the cut in all directions; and then complete cut tests until aligned correctly.  My guess is we got lucky. We didn’t have to correct the offset in our training session because the label aligned with the die-cut line perfectly after our first cut test.

Adjust Media Offset

Once completed, select “COPY MODE ON” to preselect the number of copies you want.  At this stage, we still wanted only a few to ensure the cut is correct.

Now we get into the hard part of the media path (at least I found this part difficult).

Place Thru Rollers

Twelfth, run the media down through the aluminum rollers.  Adjust the edge guides to maintain the media straight.

Thread Under Damper

Thirteenth, run the labels under the second damper arm and up and over the thick aluminum roller, down and under the thin roller as shown on the photo below.

Place Over Roller Into Slitter

Fourteenth, place a core onto the waste rewinder; then the pull off the waste matrix once the labels are fed under the roller and connect it to the core.

Connect Waste Matrix To Core

Then you can push down the waste press.  And then close the sponge roller.  I’ve seen users run the waste from the outside edges into a garbage can; or can be connected to the waste roller.

Attach To Core

Fifteenth, connect the die-cut labels to the core(s) on the rewinder making sure the label media rewinds evenly.

Sixteenth, position the slitters in the correct positions on the sides, and in cases where you are die-cutting multiples labels across the media, you would position the slitters in between the labels as well.For this, you may need to purchase more slitters.

At this point you need to TURN ON the Waste Remover.

Seventeenth, If needed, you can set the backslitters which also cut the outside edges of the finished label media correctly.  Frankly, this step seemed the most difficult to me as you have to work behind the media path.  Knob “A” moves the backslitter; knob “B” sets the cut depth.

Set Backslitter

Eighteenth, Lock the backslitter lever in place by placing the pull-pin on the left side hole. (the backslitter lock pin-hole on our DLF needs some work).

After all of these steps, you can run the job.

And here is a video of the DLF220S cutting Circle Label.

To see Afinia’s official directions, download the DLF-220S User Manual here:

In this simple stepwise recommendation, I attempted to make a relatively complicated process easy.  It doesn’t include possible adjustments required to get the die cut exactly correct; or how to set up the art/cut file.  But I hope it helps you speed up the process of becoming comfortable running the DLF220S.  And help you reduce the waste produced in training to use this machine.

Tony says, "No doubt, the DLF2220S is a great tool to have at your disposal when laminating custom-size die-cut labels.   Once you get past that learning curve that every new user has to experience, the DLF220S will produce beautiful custom die-cut labels.  Compare to other large format printers, this puppy is relatively fast, compact, and easy to use. Again, once you figure out how everything works and you get the machine dialed in, the sky is the limit for creating any shaped-size label"

I’m lucky to have Tony work with me/us on the DLF220S.  He was very patient with me; and a lot of help.

Together with the L801, the DLF220S can help you make the labels you need, when you need them; and at some of the lowest costs available.  If you need to make a lot of different labels, contact us to learn more about the DLF220S.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com 

 

Epson Warranty Changes

On April 1^st, 2021, Epson announced changes to their Extended Warranty program.  Let me tell you about why you should purchase Extended Warranties and the options available.

According to Epson, 3 reasons exist on why you should purchase Epson’s Extended warranty on their ColorWorks printers:

Why Extended Warranty

First, Extended Warranty protects your investment in a color label printer.  As I see it, X years of Extended Warranty ensures your color label printer will work during this period.  If it breaks and needs repair, Epson will fix it or replace it.

Second, and most important from my perspective, Extended Warranties insure maximum uptime.  If label printing is the critical path to shipping orders, you can’t afford to have a printer need repair, taking 2 weeks to fix.  Extended Warranties insure you can get back to work as soon as possible.

Third, Extended Warranties let’s you focus on the business at hand and not on worrying about your label printer. Plus your potential repair costs are already budgeted with “No Surprises”.

Epson ColorWorks Printers

For Extended Warranties, Epson offers 3 types; but generally, we sell only two.  On the C3500 and C6000 series color label printers, we recommend Spare In The Air (SITA) warranties.  SITA is a whole unit exchange, with next business day shipping.  I say that SITA is almost like having a “Hot Swap” label printer without actually purchasing a backup printer.

On the C7500 or C7500G, we recommend On-Site Service.  Given the size, weight of the C7500; and likelihood of damage in shipment, Epson doesn’t offer SITA on this printer.  Instead, Epson has a certified technician come on site.  Depending on the location of the printer and the time of the call, the technician may arrive on-site as soon as next day meeting parts that are shipped over night. 

On all these printers, Epson offers as well return to depot service.  This repair option takes no more than 3 days inside Epson plus the time to ship back and forth.  Generally, we’ve found this repair option taking generally two weeks from the time the printer is shipped to Indianapolis, Epson’s repair depot.

Given the time to get the printer back and the various prices of Extended Warranty, we recommend either the on-site or SITA programs.  When a printer needs repairs, most customers do not want to wait 2 weeks to get their printer back; causing frustration and production problems.

According to our Epson Sales Manager for Epson, “the Extended Warranties include printheads.  Most other color label printer manufacturers consider printheads as consumable items, and need replacing periodically.  Epson Precision Core Technology printheads are designed to work for the life of the printer. If a nozzle gets permanently plugged, Epson will replace the printhead if covered under the Extended Warranty program.”

Learn more about the Epson Preferred Plus Extended Warranties here:

And on these printers, you can get coverage up to 5 years.  To confirm your Epson color label printer is still covered by an Extended Warranty or to purchase additional years of coverage, email here with the model and serial number.  We’ll confirm the current status of your warranty and the status of purchasing additional years.

You might find Epson’s official statement on the Preferred Plus Program of interest: 

Epson Preferred Plus extended service programs offer the one assurance customers look for most: peace of mind. It comes from knowing you have a dedicated partner who is there when you need them to quickly help keep you up and running—because we understand there’s simply no time for downtime. You can also be confident when a repair is necessary, your equipment will be serviced by an Epson® Certified Technician using genuine Epson parts. We know protecting your investment is important. That’s why we offer a variety of plan options to choose from, which provide predictable pricing and make it easy to manage costs. No one knows our products better than Epson Certified Technicians. If a repair is required, we’re here to make sure your product continues to function as an essential tool and help you minimize downtime.

 

Epson’s Extended Warranties are an important addition to your purchase of a color label printer.  This plan ensures your label printers are ready to work for you.  Contact us to learn more about Extended Warranties options on your Epson color label printers.

Guy Mikel

855-962-7670

info@colorlabelsolutions.com