Tarkett, the flooring manufacturer, labels its PVC flooring using Zetes applicators. Its customised solution automatically accomodates diverse product dimensions and checks barcodes using integrated scanners.

Wood, tiles and chips - the range of patterns and motifs on Tarkett’s flexible PVC flooring is huge. With approximately 9,200 employees and 32 manufacturing sites, the manufacturer serves customers in over 100 countries. At its German plant in Konz, large flooring reels of different sizes are churned out every 30 seconds.

Three labels are automatically affixed to reels, each carrying article and ordering data. Since November 2011, Tarkett has used two applicators specially developed by Zetes to apply its labels. They are mounted directly on a rail over the end of the reel line, onto which they can move horizontally and vertically.

Exact positioning

A large label is pasted by one of the machines from above onto the wound reel and affixed onto the curved surface by a small roller. This label contains all the product information and logos. Printing data for the label is sent to the applicator directly from Tarkett’s HYDRA MES system, together with the role’s dimensions. At the same time, this provides information about the applicator’s position for affixing the label, which is transmitted via a PLC control unit to the conveyor system.

The two smaller labels must be positioned accurately. " These are used for rapid identification of the reels in the warehouse and during shipping ," emphasises Lothar Hein, the system administrator.

Zetes’ smart technical approach was what convinced us.

Tarkett

A two-part applicator plate

The second applicator also receives the print data and reel size directly from the MES system and has its own PLC control. But in this case not only do the dimensions of the reels vary, but also the size of the plugs or brims. Zetes solved this problem using a two-part applicator plate. The distance between the two parts can be adjusted as required and adapted exactly for each plug. This is done immediately after the label dispenser has dispensed the two labels on the applicator plates.

The correct height of the applicator is measured with an optical sensor. Another special feature of the second applicator is the scanner coupled to it. This means the readability of each label pasted is checked immediately. In addition, captured data is transmitted as a production document to the HYDRA MES system and the entire labelling process takes no longer than 15 seconds.

Smart approach

Zetes’ applicator solution has been running without a hitch for almost a year. " Each reel contains 3,000 labels, which lasts us for about four days ," explains Lothar Hein.

The precise and automatic positioning of labels on the different sized wheels, however, was the project’s biggest technical challenge and one that Zetes overcame in just eight weeks. " Zetes’ smart technical approach was what ultimately convinced us ," recalls Mr Hein and adds: " Another of Zetes’ strengths is the far-reaching personal commitment of its employees who, before and during the project, were always by our sides with constructive input ".

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