Benefits of 2D Barcode Printing Systems in Sawmills & Forestry

Transcription

1 JET MARKING SYSTEMS Benefits of 2D Barcode Printing Systems in Sawmills & Forestry At Jet Marking Systems, our team works every day to diagnose and resolve costly packaging and labeling issues. By integrating the technology of a Leibinger CIJ printer and Microscan AutoVision camera, we have assembled a system to eliminate commonly found human error typically introduced in the packaging process of a lumber planer mill. Our knowledgeable and experienced Service Manager, Mark O Brien was instrumental in providing such a system currently in operation at a large Canadian lumber producer. In this article, Mark provides a basic overview of the project and its benefits to the bottom line when automating the packaging process. 1

2 INTRODUCTION We are currently seeing an increase in the number of lumber planer mills automating the unitizing (strapping), wrapping, and labeling of packages. Besides reducing labour costs, there are two great benefits of automating these processes. First, when automation is introduced it minimizes the chances that the product will be packaged incorrectly. Secondly, automation eliminates the costs associated with repackaging, or worst yet, dealing with claims from buyers. Typically packaging errors happen when human error is introduced at the stacker, strapper, wrap station, and label printer. The Root Cause of the Problem When we encounter these problems, there is generally one or more of these four scenarios currently running in the planer mill: The packaging worker manually selects load label to identify the package: high possibility for error. The stacker operator hand-writes the load ID on the load with a marker: high possibility for error. The tracking algorithm in PLC remembers a load ID from the bin location to the end of finishing. This can be very risky, as there is no guarantee the load will reach the wrap station and maintain ID the whole way. This can be especially difficult if two sorter lines enter one auto wrap station. The strapper operation requires an employee to manually select options for each grade and size of load. This can create a high labour cost. 2

3 How Does Jet Marking Systems Provide the Solution? We print a 2D barcode on every board that contains the load ID (grade, length, bin number, etc.). All boards in each sorter bin will contain the same load ID. The printer is located at the existing grade print station, before the sorter. The stacker operator ensures the top tier of boards has the grade stamp and 2D codes facing up, so they are visible for the vision camera to read as the load transitions to packaging. Vision system cameras are placed across infeed conveyors at the strapper and/or the auto wrap stations. The vision system is ethernet-capable. The unique load ID number is read and passed to the PLC, via ethernet, for processing into strapper, wrapper, or printing control. The system is particularly suited to automated strapping and wrapping systems. The 2D codes are printed on all boards as they pass the existing grade stamp system. 3

4 The Leibinger Jet3 printer and a Microscan ID-40 reader are mounted suspended over the lumber line at the entry to the sorter. 4

5 The Leibinger printer places the 2D matrix code, then the Microscan imager verifies it has been printed. 5

6 COMMON Q&A How does this system compete in terms of cost? Printing on every board sounds expensive. We use a Continuous Ink Jet (CIJ) printer to produce the 2D codes on each board. The CIJ printer uses small dots of ink to create the 2D matrix code. It is 6mm high by 12 mm long. On average, the CIJ will code 2,500 boards per dollar of consumables. What happens if the code is misread? We use the ECC200 2D matrix code which features built-in error checking. This code cannot be misread, it can only fail to read. We print multiple codes per board to ensure each board has a readable code. We also read multiple boards to ensure the load ID is confirmed. On Northern Pine, the readability of the matrix codes is over 97%. By reading more than one code the failure to ID a load is much less than 1%. What if the printer fails to print? A reader is mounted directly after the printer to verify the 2D code is there. If not, the reader alarms the PLC. How difficult is the system to use? We use custom Windows based, PC software to integrate the printer, readers, and mill PLC. On one work station you can control multiple printer/reader systems. The printers typically require very little maintenance. Cleaning the print head once a week is typical. Adding ink and solvent is done off the lumber line and no stoppage is required. Starting the printer after an extended shutdown is as simple as pushing a button. Aside from cleaning the lens cover occasionally, the readers are maintenance-free How does the ID number control the strapper or wrapper? The ID will be cross-referenced with a table of all the load configurations produced (SKUs) in the PLC. From that data, a load wrap/strap configuration is chosen. A 6-digit 2D matrix produced number can decode 256 different packages and provide the bin location. As new products are added, the software automatically creates a new load ID. The Smartally controller takes the grade system data and creates the print job for both printers. It manages the readers, and generates any faults for the mill s warning system. The Leibinger Printer controllers are installed for easy access at the sorter infeed. 6

7 The wood gets stacked at the end of the sorter line. The 2D Matrix codes are placed facing up on the top tier so they can be processed at the DO2. Microscan ID-40 readers are located at the infeed to the DO2 auto wrap system. The 2D Matrix is read as the load passes below it. The readers can also send the load ID info to the wrapper for selecting the correct wrap & label content. 7

8 CONTACT US TODAY Mark O Brien, Service Manager Jet Marking Systems mark@jet-marking.com Terry Smith, Sales Representative Jet Marking Systems terry@jet-marking.com Jet Marking Systems (JMS) was established in 2005 after the ambitious team at Jet Label & Packaging identified a significant need from some of their major label customers. Since then, JMS has set out to ensure their customers always have a trustworthy, flexible support team to automate and streamline processes and to minimize downtime of their marking systems. JMS has a factory- and industry-trained team with a pool of dynamic and dedicated technicians that cover all of Western Canada. We have carefully selected and partnered with first class technology and manufacturers of coding, labelling, case sealing, tracking & traceability, RFID and conveyor systems to offer you the very best options for your industry. Questions? Visit our web site at or call us toll-free at