Diversified Labeling Solutions has been on a tear -- an aggressive focus on automated production and dedicated customer assistance has helped the Itasca, IL-based pressure sensitive label converter to achieve annual revenues topping $36 million. To accommodate continuing growth without compromising on-time delivery and personal attention, company president Bob Hakman recently consolidated three smaller facilities into a single state-of-the-art facility. The new 140,000 sq ft headquarters includes 25 label presses, several inspection stations, a warehouse, and offices, all in a pristine environment more typical of a pharmaceutical plant than a label printing plant.

The new facility is a shining example of how implementing an automation program can boost efficiency, promote line uptime, and drive costs out of the process. Hakman's plan to stage investments in automated equipment such as turret rewinders, inspection systems, and a custom-designed, automated matrix waste removal system has reached over a million dollars, yet the returns in streamlining workflow, speeding production, strengthening quality assurance, and reducing costs in both raw material and personnel have already proven to be substantial, he says.

"Integrating automated equipment into the process immediately eliminates a number of mundane tasks that can get in the way of productivity," says Hakman, who founded the company in 1985.

"Now our people can stay focused on the job at hand instead of being concerned about rewinding matrix, and that's just one example of where we've seen immediate returns," he goes on, referring to the impact of his automated matrix waste removal system from Precision AirConvey Corp (PAC), Newark, DE. Hakman is a vocal fan of the company's engineering and technology.

Waste Disposal -- Streamlined

The system captures the sticky matrix waste at the press, cuts it into pieces, and pneumatically evacuates it through a network of overhead ductwork right into a compactor with virtually no human involvement. Unsightly waste collection bins overflowing with sticky matrix waste are a thing of the past, as are countless trips hauling the collection bins through the facility for emptying and disposal. In addition, densified waste is far easier to manage, and valuable floor space is opened to accommodate other equipment.

"The PAC system has made a substantial contribution to keeping the work environment clean and uncluttered," says Hakman. "It's hard to quantify that on the balance sheet but it's something our people can feel and it translates to their commitment and performance on the job."

Hakman credits his PAC system with cutting thousands of dollars from his raw material costs -- per day. Since its installation, rewinding matrix and its requisite line stoppages have been virtually eliminated. Line uptime and product quality and consistency have improved. Budgeting for lost material has been curtailed. Best of all, the PAC system has enabled the company to purchase its material in widths that save over 2.5% in material costs. In this high-volume operation, such a change translates directly to a savings of more than $2,000 every day -- or more than $500,000 per year. "The savings in raw material alone paid for the entire system in just over a year," says Hakman.

Non-Stick Coating Is Key

PAC custom designed the Diversified Labeling Solutions system based on its PSA matrix-handling platform. Proven in more than 100 label-converting installations worldwide, the system incorporates the company's proprietary non-stick coating, which nullifies the stickiness of the adhesive. As the matrix leaves the press, it slides through the infeed to the cutter, where it is quietly cut into manageable little pieces and whisked away overhead to a rear area.

The non-stick coating ensures that the matrix moves smoothly without sticking or clogging, while a multifaceted sound attenuation system keeps the sound at a gentle hum that is far below OSHA guidelines. After the conveying air and momentum are removed in a slant screen separator, the cut matrix lands gently in a compactor outside, dust is safely removed, and the clean air is returned to the plant environment, all without requiring staff attention.

Its design also accommodates expansion as presses are added.

"We worked very closely with Bob [Hakman] to design the system based on the current and future needs of his new plant as well as the needs of his customers and employees," says Tom Embley, CEO of Precision AirConvey. "Bob is running the state-of-the-art in matrix removal now and we're grateful he involved us as early in the facility design process as he did."

Redesigning Workflow

Although it seems like a welcome engineering marvel, the new system not only improved the workflow, but also changed it, which can sometimes be unsettling.

"Our people were wary of it at first but then everyone realized how much smoother and easier it made the whole production process, and now everyone loves it," says Ken Bozelka, operations manager. "It's an incredible time-saver."

The system was continuously running up to the peak performance anticipated a few weeks after installation and testing, recounts Bozelka, but PAC's follow-through accelerated the process.

"I asked their salesman about a situation in the dust collector and within minutes he was inside the machine and covered in dirt and grime. Then he showed me an easy way to prevent it from ever happening again," says Bozelka. "They're as committed to their customers and as willing to get their hands dirty as we are. I appreciate that."

Says Hakman, "There is no doubt in my mind that Precision AirConvey makes the most effective matrix removal system in the world. Now I can be even more confident in offering my customers tight production and delivery schedules without risking a compromise in quality or personal service."