The dynamic landscape of modern FMCG manufacturing calls for fast-paced, highly reliable manufacturing processes to keep up with the high production rates required to meet market demands, satisfy customers, and stay competitive.
It is, therefore, crucial that all production steps run smoothly and seamlessly; this includes the coding and marking process.
CO2 lasers can be an ideal coding and marking solution for many FMCG applications, providing high-speed, high-quality, reliable coding. For the most part, 30 or 60 watt lasers are used to satisfy the high demands of the industry. Domino also offers a 100-watt solution.
In this blog, we will explore why some manufacturers will find benefits in using a highly powered 100 watt CO2 Laser solution.
Coding challenges
FMCG manufacturers face four main challenges when setting up the coding process:
- Speed: coding solutions need to be fast enough to keep up with the product line speeds.
- Code quality: codes must be clear and readable – poor print or code quality can lead to rejects, cause product waste, and the need for operator intervention and line stops.
- Downtime: stopping production for any reason will impact line efficiency; some downtime is unavoidable and can be planned to minimise the impact, but unplanned downtime due to error or machine failure is a manufacturer’s worst nightmare. Which brings us straight to the next point:
- Reliability: a coding solution that runs reliably in the background without needing attention, intervention, or regular maintenance for extended runs is every manufacturer’s dream.
Addressing these challenges starts with selecting an expert partner who will take the time to look into your individual requirements to help find the best fit for your production environment.
A laser solution is a popular choice among FMCG manufacturers. CO2 lasers can code a range of materials, from paper and card to glass, PET, and other plastics. Domino’s CO2 lasers have a reputation for running reliably and with minimal downtime while providing great print quality.
Is power the solution?
Generally, increasing the power of a laser can lead to improvements:
- Higher-powered lasers can typically code harder materials; a good example is coding glass, which requires a 60 Watt laser at least to mark the glass surface effectively
- As laser power increases, so too does speed capability - additional power can help to increase line speed, or maintain speed while increasing the number of characters printed
- Constantly testing the limits of a laser can lead to increased wear and faster ageing; adding a power reserve can help to increase reliability and longevity
For a future-proof, reliable solution that can be operated for many years, it is beneficial to install a laser solution that offers more power than is absolutely necessary; for production lines running at medium speeds and printing on materials such as paper or card, a 30 watt laser is likely to be sufficient; while manufacturers printing manufacturing data on plastic shampoo bottles at speed would be better suited to a 60 watt CO2 Laser solution.
But if your production demands large label formats, including graphics and machine-readable codes (MRCs), at high line speeds, a 100 watt laser can help ensure that you meet your target. For example, labelless bottles, which are gaining interest in the beverage industry, will require the high-power, high-speed capabilities of a 100-watt laser to replicate the contents of entire labels, including ingredient lists and barcodes.
Likewise many high-speed pharmaceutical lines with coding requirements on plastic single dose injectors benefit from 100 watt laser power.
At Domino, we are also seeing increased demand for our D1020i 100 watt CO2 laser for printing on glass bottles for premium beverage brands: often, this is to satisfy demands for high-quality prints that complement the branding and design of bottles for luxury drinks.
Lastly, manufacturers dealing with products produced during very long production runs at extremely high speeds will also benefit from a 100-watt CO2 laser; in these applications, the 100 watt laser offers a superior alternative to wax or hot stamp coding methods, ensuring improved reliability and efficiency.
Don’t take our word for it, listen to our customers
A pharmaceutical manufacturer based in Germany required a coding solution for vaccines in a blow-fill-seal machine on a high-speed packaging line for sterile liquids.
Installing Domino’s D1020i 100W CO2 laser proved to be a game-changer in their production: The laser helped to significantly increase line uptime to more than 90% and minimise the need for human intervention. This improvement in uptime was considered revolutionary, allowing the production of 25,000 injectors per hour on each line. The D1020i also played a crucial role in meeting the stringent requirements of the vaccine production process.
Our customer has been operating the D1020i for more than three years to date without any issues, stating:
‘The D1020i has demonstrated impressive efficiency, achieving a very short marking time of only 1.3 seconds per 8 vaccine injectors. The installation of the D1020i has facilitated the continuous filling process in our production by helping to reduce human intervention and the associated risk of contamination.’
Does premium cost a premium?
While the initial capital investment in a 100 watt CO2 laser is higher than in a lower powered variant, manufacturers installing a D1020i 100 watt CO2 laser may, in fact, benefit from reduced costs in the long run. This is because the TCO (total cost of ownership) is lower compared to other coding solutions: the benefits in terms of increased uptime, reduced product waste, savings in consumable costs, and improved longevity more than compensate for an initially higher expense.
In addition, Domino offers flexible financing and leasing options to remove the stress of acquiring technology. So you can upgrade your production and enjoy the benefits of the latest coding technology without capital expenditure.
In a nutshell
The 100 watt CO2 laser stands out as a high-powered solution designed for high-speed coding on various materials, including glass and plastics. It provides high production speeds, superior code quality, and outstanding reliability and longevity.
Domino’s 100 watt lasers offer a superior alternative to wax or hot stamp coding methods, helping to ensure reliable and efficient coding. They are ideally suited to long-run production, reaching up to 99% uptime.
At Domino, we understand the importance of reliability and seamless integration into your operations. This is why we take the time to find and test different potential solutions until we find the optimal solution for your individual application. We don’t stop at the printer but can take care of your complete coding process, including laser safeguarding and extraction, as well as options for automating your coding processes.
