Low-melt labeling solution ensures batch integrity.

Like many suppliers to the automotive industry, process control and lot traceability are extremely important to Paulstra, a manufacturer of anti-vibration systems and components. Unlike many other manufacturers, the bags Paulstra uses to hold materials used in production get melted down in the process and ultimately become part of the product itself. Tracking the bags and ensuring the right materials are used in the right batch proved to be extremely challenging. Handwritten identification on the bags is often illegible and inaccurate, while traditional bar code labeling is impossible because the label material contaminates the rubber product being formulated.

More than 100 chemical ingredients go into each of the rubber mixes that Paulstra produces each day at its facility in Grand Rapids, MI. Powdered chemicals are measured and sealed into bags made of Lomel material, which can be safely melted into the rubber batch. If just one wrong bag is added to the mix, the batch is unusable, resulting in waste and disposal costs that can reach tens of thousands of dollars. Bags themselves are unusable and must be thrown away if they cannot be identified.

"Pens did not work because the ink would often smear and handwriting was not always legible," said Sebastien Lebon, mixing process engineer at Paulstra. "We also tried printed tags, using a thermal printer, but the tags could not be adhered to the bag because any paper material would contaminate the product. We tried various methods of temporarily attaching the tags, but we could not prevent the tags from becoming separated from the bags. These methods were not 100% reliable, and unmarked bags resulted in material loss and disposal costs."

Paulstra shared its problem with Paragon Data Systems, which specializes in developing and integrating automatic identification systems. After extensive development and testing, Paragon created a patented method for printing directly on the same Lomel film material that the bags are made from. Lomel film is used, together with high-quality thermal-transfer printers and ribbons from a manufacturer of printers to produce labels that can be applied to bags without impacting the production process.

"I would not trust any printer but a Zebra 105SL or Xi series for this application, because it requires top quality," said David Safenovitz of Paragon Data Systems. "The Lomel film is very sensitive."

This system is said to prevent waste from unidentified bags and has led to a major reduction in mixing errors. With a bad batch costing upwards of $10,000 in lost materials and disposal expenses, the system is said to have returned tremendous value to Paulstra.

Zebra Technologies 

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