Label Printing

Motion control for label printing and processing – ensuring every detail is perfect

Small batch sizes, high delivery pressure, and frequent job changes represent a constant challenge for machine operators in label printing and processing. At the same time, demands in terms of register fidelity, consistently regulated tension, and reproducible printing quality are increasing. This must be reliably guaranteed even with thin films, multi-web applications, or demanding finishing processes. Added to this are increasingly stringent requirements for sustainability (e.g. the PPWR), machine safety, and cybersecurity.

This necessitates an automation solution that combines performance, safety, security, and sustainability. The preconfigured Solution Set for "Label Printing and Processing" set based on ctrlX AUTOMATION combines powerful motion control, open system architecture, and efficient engineering. This allows printing and converting processes to be quickly adapted, reliably synchronized, and operated in a way that conserves resources – for maximum productivity in modern packaging processes.

The image shows a machine printing labels. A color filter with a blue-to-red gradient has been applied to the image.

Your benefits for label printing at a glance:

• Maximum register fidelity at full speed

• Stable tension even with the thinnest materials

• Jobs can be changed at the push of a button, resulting in less waste

• Secure, open, and ready for the CRA

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Automation for label printing and processing in a set

The picture shows a real factory environment with a label printing machine. Hexago-nal honeycombs are depicted. Within these honeycombs, the solution components of the solution set are illustrated.

The Solution Set "Label Printing and Processing" is a pre-configured automation bundle for label printing and converting with ctrlX AUTOMATION. It is based on ctrlX CORE, ctrlX MOTION, ctrlX DRIVE, motors, and rapid ctrlX I/O – supplemented by ctrlX HMI, safety functions, and open communication interfaces.

The high-performance motion control with electronic gear, electronic cam, and FlexProfile allows high-precision synchronization of printing and converting machine modules. Consistently regulated tension and high-precision control of the printing cylinders and finishing stations ensure reproducible quality in label printing. Profitability is ensured even with frequent format and job changes through register-accurate start-up and shutdown with minimum waste. Material consumption and energy use are optimized, which enables sustainable and modern packaging applications.

"Parameterizing instead of programming" is the motto. App technology and software templates significantly shorten engineering and commissioning, leaving time to focus on what is important: precise process control. With integrated functional safety and security by design, the system is also prepared for increasing requirements such as the Cyber Resilience Act (CRA).

This picture shows the topology for a label printing machine. It displays the solution components of the solution set: ctrlX CORE, ctrlX SAFETY, ctrlX DRIVE, ctrlX HMI, as well as ctrlX OS and partner apps.This picture shows the topology for a label print

Example application for label printing

ctrlX CORE with ctrlX MOTION synchronizes printing and converting axes via ctrlX DRIVE. ctrlX I/O is connected via EtherCAT, allowing inspection systems to be synchronized with high precision. ctrlX HMI allows browser-based operation. ctrlX SAFETY can be added as an option. Open interfaces (OPC UA) integrate third-party systems.

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ctrlX OS Community

Do you need further assistance? In the ctrlX OS Community you will find blog posts, GitHub applications, and how-to articles on topics related to label printing and many other application areas of ctrlX AUTOMATION.

Go to ctrlX OS Community!

Hardware and software components of the solution set

This image displays the control platform ctrlX CORE. Alongside it is the app icon for ctrlX OS, the Linux-based operating system that runs on the control.

ctrlX CORE – Control platform with motion DNA

The control platform ctrlX CORE combines PLC, motion control, and communication in a compact platform. The open operating system ctrlX OS with app technology allows flexible extensions and simple integration into existing printing and packaging systems. Security by design creates a future-proof basis for CRA-compliant machine concepts.

ctrlX MOTION – Precise motion control for register fidelity

ctrlX MOTION realizes highly dynamic, synchronized movement sequences for label printing and converting. The electronic gear, electronic cam, and FlexProfile enable register-accurate multi-color printing, controlled start-up and stoppage, and consistently controlled tension – all critical factors for quality and productivity in label printing.

Shown are various products from the ctrlX DRIVE family: a servo terminal for the ex-tra-low voltage range, cabinet-free servo drive technology, a modular servo drive, and a servo motor.

ctrlX DRIVE – Dynamic drive technology

The modular ctrlX DRIVE ensures precise axis movements and high dynamics in printing and converting processes. When combined with ctrlX MOTION, the result is a consistent motion architecture that ensures the highest register accuracy and stable process results – even at high speeds.

The image shows various ctrlX I/O modules connected to a bus coupler.

ctrlX I/O – Rapid signal processing

ctrlX I/O provides integrated sensors and actuators with short cycle times via EtherCAT. This enables precise process control and stable web guidance in label printing – for less waste, greater efficiency, and reproducible quality.

The image shows the safety control ctrlX SAFETY.

ctrlX SAFETY – Integrated machine safety

ctrlX SAFETY adds scalable safety features to the solution set bundle: from safe I/Os to safety control. This reduces engineering work and supports standard-compliant machine concepts for international markets.

The image shows various ctrlX HMI devices, such as displays, web panels, housed panel PCs, and other devices from the ctrlX HMI portfolio.

ctrlX HMI – Web-based visualization

ctrlX HMI enables browser-based operation, quick format changes, and transparent diagnostics. Operators benefit from clear interfaces, shorter changeover times, and efficient service – all vitally important for frequent job changes in label printing.

ctrlX PLC – IEC 61131-3 logic

The ctrlX PLC app implements automation logic in structured text (IEC 61131-3) and seamlessly combines with ctrlX MOTION. Reusable software modules reduce development times and accelerate time to market.

The image shows the app icon EtherCAT Master.

EtherCAT Master – Deterministic real-time

The EtherCAT Master app ensures precise synchronization between the control system, I/O, and drives. Low cycle times form the basis for high-performance motion control in label printing – especially in multi-color printing and dynamic conversion processes.

OPC UA – Open communication

With OPC UA server and client, inspection systems, control systems, and third-party components can be integrated in a standardized manner. This creates transparency, supports 100% in-line quality control, and strengthens the future viability of modern packaging systems.

The image shows the app icon for the partner solution Remote Service from IXON.

Optional: IXON – Remote service

The ctrlX World partner solution from IXON enables secure remote access, monitoring, and rapid support. This reduces downtime and increases system availability.

The image shows the app icon for the partner solution WebIQ.

Optional: WebIQ – Flexible web visualization

WebIQ is a powerful web HMI solution that complements the bundle. The flexible configuration supports modern operating concepts in label printing and processing.

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