Thermal-transfer goes four-color process

Scimed Life Systems uses up its $250ꯠ preprinted label stock inventory in favor of on-demand high-quality four-color process thermal-transfer printing. Label stock changeover drops from 20 per shift to just over one.

Scimed?s color thermal-transfer-printed label is virtually indistinguishable from its previous preprinted label, shown at right
Scimed?s color thermal-transfer-printed label is virtually indistinguishable from its previous preprinted label, shown at right

When color thermal-transfer printing debuted about a year and a half ago, it was a great idea whose time had come a bit too soon. Early printer models were said to be plagued with poor software, slow print times, registration problems and costly ribbons. Today a second generation of color thermal-transfer printers has made significant strides, causing a lot of packagers to take a second look.

One of the first companies to adopt this new version of color thermal-transfer printing technology was Maple Grove, MN-based Scimed Life Systems, a division of Boston Scientific Corp. A fast-growing manufacturer of medical devices, Scimed had been applying preprinted color labels-overprinted with variable data from a standard thermal-transfer printer-to preformed Tyvek pouches containing its guide wire products used in angioplasty surgery. The company had been stocking as many as 70 preprinted label formats, including labels for outer cartons.

While the preprinted labels looked great, it was becoming a burden to manage the label inventory due to the company's rapid growth and expanding product line. And since it packages products in small batches of 40 to 60, operators found themselves switching heavy preprinted rolls 15 to 20 times per shift. Another problem was that label design changes were making labels in inventory obsolete and took months to carry out.

Scimed knew it had to switch to on-demand printing, but it didn't want to be confined to black-only printing. Color labels quickly convey key aspects and features of the company's products. Solving both problems was a pair of Sundance 300-dpi four-color thermal-transfer printers from QuickLabel Systems (West Warwick, RI). They were installed in Scimed's Plymouth, MN, production facility in October '95. Computerized Machinery Systems, Inc., Labelmart Div. (Plymouth, MN), which actually sold and installed the printers, served as the distributor and ribbon advisor. Since then, Scimed has totally eliminated preprinted labels.

The benefits from this change are plenty. First, instead of tracking 70+ different preprinted labels, Scimed now uses two unprinted generic sizes. From a cost perspective, Scimed manufacturing engineer Bill Verkuilen estimates that Scimed eliminated a preprint inventory valued in excess of $250ꯠ. "That doesn't include warehouse space costs, purchasing costs, receiving inspection costs, transportation to the packaging area, and delays in production due to frequent changeover," Verkuilen adds.

This is perhaps the biggest benefit as the company's growth continues unabated. (Verkuilen recounts that upon joining the company three years ago, Scimed was producing about 200 wires per month; by the end of this year, Scimed forecasts closer to 50ꯠ/mo.)

Another benefit is speedy design changes. Before it could take up to three months to produce a new label design-including printer lead times, plate making times, and separate internal approvals for both the preprint and the variable print specs. Such changes can now can be done in a week or two, which consists mostly of waiting to obtain the necessary internal approvals; minor changes can be done in as little as a day.

Color craziness

In looking at a variety of color printing technologies-thermal-transfer, laser and ink-jet-Verkuilen had to sift through a variety of pluses and minuses. "Some printers were either significantly over our budget, and others took as long as 10 to 15 minutes to download the initial label format."

QuickLabel Systems Sundance printer seemed to overcome most of these problems gracefully enough. Initial label download takes about 45 seconds for the first label of the day. Once the graphics and foreign-language characters in Japanese (one of six languages on the label) are downloaded, the printer keeps that information in memory until it's turned off. Result: subsequent first-label-out times are almost instantaneous, especially if label content changes are minor from run to run.

The printer's four printheads each employ a different color ribbon (cyan, magenta, yellow and black). However, much like a traditional four-color press, each printhead can lay down a color either in full 100% coverage or in a percentage of coverage, e.g., 10%. By combining different colors at 100% coverage, up to seven solid colors can be produced by the printer. Unlike another color thermal-transfer printer that Verkuilen evaluated, the Sundance has the ability to simulate thousands of other colors by using true process printing, also known as "dithering." This technique involves mixing multiple colors in varying dot patterns or screen percentages, like a newspaper photograph.

List: Digitalization Companies From PACK EXPO
Looking for CPG-focused digital transformation solutions? Download our editor-curated list from PACK EXPO featuring top companies offering warehouse management, ERP, digital twin, and MES software with supply chain visibility and analytics capabilities—all tailored specifically for CPG operations.
Download Now
List: Digitalization Companies From PACK EXPO
Annual Outlook Report: Automation & Robotics
What's in store for CPGs in 2025 and beyond? <i>Packaging World</i> editors explore the survey responses from 118 brand owners, CPG, and FMCG <i>Packaging World</i> readers for its new Annual Outlook Report.
Download
Annual Outlook Report: Automation & Robotics