Label changes are a critical component in the can manufacturing process. If not optimized, they can lead to significant downtime and lost production.  In this video, Alex Garcia, shares strategies and techniques that have proven effective in reducing label change times, drawing from experience at a can plant in Brazil where label changes were reduced from over an hour to an average of seven minutes.

An effective label change begins with a well-organized external setup. This phase includes all tasks that can be completed while the machine is running, ensuring that when the machine stops, the team is ready to start the label change without delay. Preparation includes:

By completing these tasks in advance, downtime is minimized, and the changeover can proceed without interruption.

The label change itself involves three main steps:

1) Washing the Inkers: Clean inkers thoroughly to prepare for new colors.

2) Replacing Printing Plates: Switch out old printing plates for the new set.

3) Changing Blankets: Replace blankets to ensure high print quality.

Separating tasks between external and internal setups allows each operator to focus on specific responsibilities, streamlining the overall process.

Using tools like pneumatic, impact wrenches for cylinder removal can significantly cut down on time. These tools enable quick removal of components without manual effort, expediting the changeover. Additionally, inker cleaners (for Rutherford style decorators) can help control ink splashing during inker cleaning, allowing for a faster and cleaner process.

When labels are scheduled for change, color sequence planning can reduce the need for full inker cleaning. Grouping labels with similar colors—such as red, white, and black—minimizes the ink transition required, thereby saving time. By pre-planning the order of label changes based on color, the need to clean all inkers is reduced.

For labels that require multiple colors, using spare plate cylinders can help minimize adjustments. Keeping the same set of cylinders for color-similar labels reduces the need for realignment and calibration. This technique is particularly effective for complex labels that involve precise registration settings.

While each plant may have unique challenges, these strategies for label change optimization can be broadly applied across different facilities. By implementing an external setup, utilizing efficient tools, sequencing label changes by color, and minimizing adjustments, can plants can significantly reduce downtime and improve overall production efficiency.