Industry 4.0 in Pad Printing

Industry 4.0 marks the next stage of industrialization. How is it implemented in pad printing? What has already been achieved, and what’s planned for the future?

Industry 4.0 represents a flexible, connected, and data-driven production approach, down to batch size one. Data is collected and used for optimization, with the goal of networking machines to allow them to self-monitor and self-optimize.

Flexibility and Batch Size One

In pad printing, significant progress has already been made. Previously, machines could only print a single image or multiple images for multicolor printing. Since 2005, the ML line, with its programmable processes and linear motors, has enabled the combination of multiple print designs on a single cliché, allowing flexible printing without needing to change the cliché. Different motifs can be printed simply by switching the application, achieving batch size one for pad printing. Although the selection of motifs is limited, various print settings can be changed manually on the display, via a barcode reader, or through a communication interface. The following video showcases the ML500E, which can print different cups without changing the cliché.

In a fully realized Industry 4.0 setup, each part to be printed receives a unique identifier. Through an RFID reader connected to the machine via IO-Link, this identifier is read, and the machine queries the company software via OPC-UA to determine the required motif or color. The product is then customized based on this information.

Industry 4.0 Batch Size One Padprinting OPC-UA and RFID

Before the part leaves the pad printing machine, it reports to the company software that the part has been printed, also providing additional data for analysis, such as pad printing parameters like pot life, temperature, humidity, or camera evaluation results.

These are not future developments—they are already part of the current state of technology.

Collecting and Analyzing Data

To achieve targeted optimization, measurement values must first be recorded. Real-time measurements enable rapid success tracking for optimizations. Thus, every improvement begins with data collection: The more data available, the more precise the insights and further optimization potential that can be identified. In pad printing, numerous parameters can be recorded, such as the fill levels of the cleaning tape and thinner reservoir, which not only indicate refilling needs early but also provide insights into consumption, enabling further optimization for reduction. Environmental factors like temperature, humidity, or vibrations can also be tracked to help identify the root causes of print issues. Wear values for clichés, rings, and pads offer insights into the lifespan of materials used, assisting in the selection of the best suppliers. Color data, such as viscosity and pot life, supports optimal timing for the next color change. A camera system provides information on position accuracy and print quality, enabling automatic adjustment of the print position and early detection of when print quality falls below standards. Not all possibilities have been implemented yet, but our capabilities in this area have expanded significantly.

Self-Optimization

With the ML and module lines, we have machines where each movement can be precisely controlled. This, along with the new data metrics, opens the door for applying artificial intelligence and machine learning to continuously and automatically optimize the printing process. This is our goal for the future and the next step towards fully realizing Industry 4.0 in pad printing.

Breaking News:

Expansion of Modul machines

Our MS Series comes now with exciting new part-handling features

Industry 4.0 in Pad Printing

Flexibility and Batch Size One

Collecting and Analyzing Data

Self-Optimization