Automated Labeling Cuts Downtime and Mislabels in Metal Stamping

White Paper

Automated Label Application Eliminates Downtime and Mislabeling in High Vibration Metal Stamping Environment

A Proven Approach to Stabilizing Label Application, Improving Quality, and Boosting Throughput
________________________________________
Executive Summary

A Midwest metal stamping manufacturer applied extremely small labels—multiple streams across—onto continuous steel webs prior to stamping. Legacy applicators could not sustain placement accuracy or uptime under heavy press vibration, causing unlabeled parts, rework, scrap, and frequent stoppages.

LabelPack Automation engineered and deployed a custom 220W snorkel equipped applicator platform rated for 300 parts per minute, with robust components, stable mounting, mirrored HMIs, oversized roll capacity, and interlocked web monitoring. Deployed across 20 lines, the system reduced downtime, improved labeling consistency and quality, accelerated changeovers, and delivered a more scalable, maintainable standard.

Problem: Mislabeling, undetected label runout, slow changeovers, and frequent applicator failures in a harsh, high vibration environment.

Solution: Custom 220W snorkel equipped applicators with robust mechanics, stable application geometry, integrated controls, and four web monitors tied to the press stop.

Outcome: Less downtime and waste, faster repeatable changeovers, improved operator experience, and stronger lifecycle support.
________________________________________
The Operational Challenge

The plant’s previous label applicators were frequently offline, with units cannibalized for parts. Operators relied on visual checks to spot label roll depletion, allowing unlabeled parts to move downstream and trigger rework or scrap. Vibration from the presses caused applicators to drift, cutting labels during stamping and compromising quality. Product changeovers were lengthy and inconsistent, slowing throughput and increasing the burden on maintenance.

These issues are common where small labels must be applied accurately at high speed across multiple lanes in a heavy industrial setting. Without reliable communication to line controls or protection against material faults, even minor issues cascade into stoppages and waste.

Root Causes

Three factors drove the plant’s challenges:
1.    Inadequate Equipment: Legacy systems were not designed for current press speeds, product variation, or the site’s vibration profile.
2.    Unstable Application Geometry: Mounting and application geometry were not stable enough to ensure repeatable placement, allowing vibration to propagate to the label point.
3.    Limited Integration: The labeler could not coordinate with the press to stop the line when material faults occurred, leading to label placement and other quality issues.
________________________________________
The LabelPack Solution

LabelPack designed a custom 220W snorkel equipped applicator platform focused on stability, speed, and lifecycle maintainability.

•    Robust Performance: Rated for press speeds up to 300 parts per minute and built with heavy-duty components suited to high-vibration environments.

•    Stable Application: A pivoted application point (snorkel) places the label onto a mechanically stable section of the steel web, drastically reducing misalignment risk.

•    Enhanced Maintainability: A lift away design provides fast access for material changes, while oversized supply roll capacity reduces changeover frequency. The system uses standard, non-proprietary components that can be sourced locally. 

•    Dual Configurations: Two configurations support both single label application and a wider web path for multiple labels, enabling a consistent standard across differing product formats.

Integration and Operator Experience

•    Seamless Control: Remote cycle start synchronizes applicators with the presses.

•    Intuitive Operation: Mirrored HMIs allow setup and operation from either side of the line. A remote light stack with an audible alarm provides clear status without leaving the workstation.

•    Repeatable Changeovers: Saved product recipes make setups faster and eliminate human error.

Fault Prevention and Quality Assurance

To prevent unlabeled parts, four safeguards are interlocked to the press stop:

1.    Low label sensor
2.    Web break sensor (before peel plate)
3.    Web break sensor (after peel plate)
4.    Motor watchdog

If any fault occurs, the press stops immediately, protecting quality and eliminating downstream rework.

________________________________________
How It Works on the Line

In production, the snorkel positions the label to a stable point on the steel, isolating the application geometry from press induced vibration. The applicator cycles in step with press timing, ensuring consistent label release and placement at speed.

Operators access mirrored HMIs to select product recipes, verify parameters, and monitor status, while the light stack and audible signal communicate faults or material outages clearly. When the system detects a low label condition, a web break, or a drive anomaly, it signals and stops the press, preventing unlabeled parts from advancing.
________________________________________
Implementation and Change Management
Customer’s Feedback
“We recently upgraded our label applicating systems across all 20 automatic metal stamping lines with customized equipment provided by LabelPack. The primary goal was to bring consistency to our operations and reduce downtime — and we have seen meaningful improvements in both areas.

One of the most impactful customizations was the addition of a sensor that stops the machine if the label roll runs out or breaks. This feature alone has helped us reduce waste and improve quality control. 

Another major improvement has been the ability to save recipes for different product setups on the HMI. This has significantly streamlined our changeover process, making it quicker and more repeatable for our set-up team.

Beyond the equipment itself, the customer service from LabelPack has been outstanding. Their team has been responsive in addressing any issues. The training experience was especially impressive — they accommodated early hours to ensure all shifts were trained, provided thorough manuals, and have remained a reliable partner throughout the process. 

LabelPack has continued to be a true partner throughout the ownership of the equipment, not just during the initial sale and installation. Their ongoing support and commitment to our success have made a lasting impact.”

Project Engineer, Metal Stamping Manufacturer in the Midwest

Labeling touches every product that leaves your facility, and small errors can cause large ripple effects. With the right equipment, materials, and engineering support before, during, and after the sale, we can help eliminate downtime and build a more scalable and accurate production.