The following is intended as a supplement to our recently published article entitled – (Crossdocking Continues To Play An Important Role In Increasing Supply Chain Efficiency).

Don’t let the requirement for compliance labeling slow down your crossdocking initiative. You can keep your crossdocking operation running smoothly and efficiently by deploying equipment that can automatically print and apply customer specific labels to every shipping carton.

Automated Print & Apply System Solution

A trailer load of palletized product consisting of a half dozen or more SKUs, is sitting on your receiving dock. All of the cases have a “case code” bar code, or ITF-14, which is basically the product UPC number plus a case pack identifier, on the side of each case. Half of this product is needed immediately to fill customer orders; the other half will replenish active pick locations or go into inventory.

For replenishment product, or for product going into inventory, a pre-printed pallet ID bar code label can be manually applied to each pallet load and then scanned along with the ITF-14. The WMS will assign an active pick slot or static storage location for put-away – no problem. However, before the remaining cases can be crossdocked, a customer specific, bar coded shipping compliant label (GS1-128 formerly called the UCC-128) must be printed and applied to each case. Getting the right bar code label onto all those cases can be a time-consuming headache. The challenge is how to get this job done quickly, accurately, and efficiently.

In the early 90’s material handling system providers developed various automated methods for systematically printing and applying shipping labels to the side, top, or end of each carton. The following illustration represents one of several integrated printer/applicator solutions:

Typical System Configuration

Printer/applicators don’t work alone. A variety of other necessary equipment makes up a complete working system. The illustration above shows a typical configuration. The following is a brief description of each major component:

De-Palletizing Station (Optional)

This optional piece of equipment addresses the ergonomic issues involved in the manual de-palletizing operation. The unit automatically positions the pallet load while eliminating the need to bend, stretch or strain. Its unique design allows the pallet to elevate as the cases are removed maintaining the top of the load at a convenient working height. The rotating top ring minimizes walking or reaching during the de-palletizing process thereby increasing productivity.

Printer/Applicator

Mounted directly to the conveyor, or on an adjustable stand, the print-and-apply machine incorporates a print engine, and an application device which uses one of several common technologies (e.g., tamp or blow-on). It also provides user settings and controls, and label media unwind and rewind devices. The applicator is mounted so that it can place the label exactly where it is needed on the case (e.g., precisely positioned on the side, top, or end).

Warning Lights

A series of colored lights on a pole, easily visible to operators, that flash to signify various errors or conditions, such as low media and “no read” bar codes.

Carton Notification Scanner

Usually a fixed-mount line or omnidirectional scanner that reads the appropriate bar code on the case, such as a license plate ID or SKU/UPC number, and relays that code to the control software.

Photo eye (P/E)

A sensor that detects the product as it moves down the conveyor and sends a signal for the applicator to print a label. Sometimes other sensors serve this purpose.

Buffer Conveyor

Can be a couple of sections of gravity roller conveyor, or if more buffer is needed, it could be a longer run of zero pressure accumulation conveyor.

Meter Conveyor

A conveyor just upstream from the applicator; it provides adequate spacing between cases to be labeled.

Skew Conveyor

A live roller conveyor, with skewed rollers, that drives the case over to the applicator side of the conveyor bed.

PC with Applicator Control Software

Can be anything from a simple label design/print package with database look-up capabilities to a more sophisticated software program that accepts downloads from the host, does database look-ups, generates printer formats and data streams, and sends data records back to the host, WMS, WCS, or some other system.

Programmable Logic Controller (PLC not shown)

The PLC provides conveyor control, such as shutting off the conveyor in the event of a “no read”. It may also be used to activate warning lights, or to actually send the firing signal to the applicator. More sophisticated controls may be used for controlling induction into the applicator system, downstream weigh in-motion scale, and the shipping sortation system.

Verification Scanner

This scanner verifies that a readable label was applied to the correct case. This information is usually sent back to the applicator or conveyor control system. If a “no read” occurs, the conveying system should shut down until the problem is resolved.

Reduction of manual labor: 

Often, the labor savings alone will justify the cost of a printer/applicator system in less than 2 years.

System throughput:

Since applicators often label product in conjunction with existing or new material handling systems, the delays inherent with manual labeling methods are eliminated and product flows smoothly through the system.

Consistency of label placement: 

Automatic applicators can position labels exactly on each case, allowing them to be scanned much more efficiently.

Data integrity:

An applicator system can eliminate the risk of the wrong label formats or data being applied to the case, avoiding costly charge backs or returns from customers.

Final Thoughts

Although shipping labels can be printed off-line and then applied manually, automating the process will eliminate errors and increase overall system performance. In addition, auto print/apply technology can be integrated with other technologies for additional benefits. For example, if you’re interested in automating your dimensional weight “DIM weight” problem - see (What Can You Do About Rising Shipping Costs).

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