Multi Layer Label Pasting Machine

It is a roll-to-roll converting machine that bonds a second label layer onto a master label. The master roll is unwound and fed under a pasting head. A second roll, carrying the labels to be applied, is fed into the head, where each label is peeled from its liner and pressed onto the master label at the set position. The combined web then passes through slitting and counting and is rewound as finished multi layer labels.

Placement is controlled by sensors. A gap sensor reads the space between labels on the applied web and a mark sensor reads a printed mark on the master, so every second label lands on the same spot of every master label. The machine runs a master label repeat from 2" to 18", applies labels from 15 mm to 180 mm and handles a repeat height of 25 mm to 100 mm. It is fully servo based with touch screen control.

Fully Servo Based Touch Screen Control

Feed, placement and stop are controlled by servo drives from a touch screen. The operator enters the label sizes and position once, and the machine repeats them for the whole roll.

Gap Sensor and Mark Sensor Placement

A position gap sensor and a mark sensor read both webs, so the applied label is placed by what is actually on the web, not by a fixed count. Mark and gap sensor facilities are standard.

Sheet Cutting Unit With Program System

A programmable sheet cutting unit with a pneumatic cutting system is part of the machine, so jobs that must be delivered as cut pieces rather than rolls can be finished on the same machine.

320 mm Machine Width and 2" to 18" Repeat

The machine handles master webs up to 320 mm wide with a master label repeat from a minimum of 2" up to 18", covering small pharma labels through large drum and carton labels.

Applied Label From 15 mm to 180 mm

The second-layer label can be anything from a small coupon or seal at 15 mm to a large leaflet label at 180 mm, with a repeat height of 25 mm to 100 mm.

Auto Unloading Unit With Gauge Unit

The unloading unit is automatic and fitted with a gauge unit; the machine is specified with a 750 mm unloading unit and 400 mm label unloading.

Nip Roll, Rotary Blade Slitting and Waste Blower

A nip roll unit feeds the web positively, rotary blade slitting cuts the combined web to finished widths, and a waste blower clears the matrix and trim from the machine.

Label Counting With Auto Stop

An electronic label counter stops the machine at the set count, so finished rolls are made to a fixed label quantity.

The master label roll is loaded on the unloading unit and threaded through the nip roll unit under the pasting head. The second label roll is loaded on its own unwind and threaded through the head, where a peel edge separates each label from its liner. The operator enters the master repeat, the applied label size and the placement position on the touch screen, and sets the mark and gap sensors.

When the machine runs, the mark sensor detects the reference mark on each master label and the servo drive feeds the applied web so that one label peels off and is pressed onto the master by the nip at exactly the set position. The gap sensor keeps the applied web in step label by label. The combined web then goes through rotary blade slitting to finished width, the waste blower removes trim, the counter counts labels and stops the machine at the set quantity, and the finished multi layer labels are rewound. Where a job needs sheets instead of rolls, the programmable pneumatic sheet cutting unit cuts the web to length.

• Pharma leaflet labels – a folded leaflet or extended-text label pasted on a base label for medicines and healthcare products.
• Promotional and coupon labels – a peel-off coupon, scratch panel or offer layer applied over the product label.
• Chemical and agrochemical labels – multi-language or multi-page instruction layers on drum and bottle labels.
• Security and seal labels – a second seal or tamper layer placed over a base label.
• Multi ply and booklet labels – bonding the layers of two- and three-layer label constructions before finishing.
• Sheeted label jobs – multi layer labels delivered as cut sheets using the sheet cutting unit.

The machine handles self-adhesive label stock on both webs: paper, chromo, thermal and film labels on a release liner as the master, and paper or film labels, leaflets or coupons on a liner as the applied layer, within the 320 mm width, 2" to 18" master repeat, 15 mm to 180 mm applied label and 25 mm to 100 mm repeat height limits. Share your actual label constructions with RK so the sensors, peel edge and nip are set for them.

• Tape Cutting Machinefully servo controlled auto slicing of tape rolls to width.
• Foam Die Cutting Machinedie cutting of foam sheets and rolls into gaskets, pads and inserts.
• Gift Wrap Ribbon Slitterslitting ribbon jumbo rolls into small retail reels.

RK Label Printing Machinery Pvt. Ltd. has built label printing and converting machinery in Ahmedabad, Gujarat since 1995, operates three manufacturing units and supplies customers in 23+ countries. Special purpose machines such as the multi layer pasting machine come from the same design and manufacturing base as RK's flexo presses, die cutters and slitters, and use the same servo, sensor and rewinding know-how. The machine is configured against the customer's label constructions, and RK's printing, die cutting and inspection machines complete the line from one supplier.

• Master label sizes: check that your master repeat falls within 2" to 18" and the web within 320 mm.
• Applied label sizes: the second layer must be between 15 mm and 180 mm, with a repeat height of 25 mm to 100 mm.
• Placement reference: decide whether your master labels carry a printed mark for the mark sensor, or whether gap sensing is enough.
• Finished form: rolls of a set label count, slit to width, or cut sheets from the sheet cutting unit.
• Roll sizes: match your incoming roll diameters to the 750 mm unloading and 400 mm label unloading specification.
• Output: tell RK your monthly quantity so the configuration is sized for it.

The price of the multi layer pasting machine depends on the configuration – sensor arrangement, slitting and sheet cutting requirements, unwinding and rewinding sizes and options. Prices are quoted ex-works Ahmedabad with GST at 18% applicable; engineer transport and stay for installation and training at your site are borne by the customer. Share your label constructions, sizes and production target with RK and the engineering team will recommend a configuration and quote against it.