Automated 55-Gallon Drum Labeling: A Case Study

LabelMill’s new print-and-apply labeling systems automate the entire labeling process for 55-gallon drums, creating cost-saving efficiency and simplicity. Here’s how they work and how they were developed into a winning solution.

■ Turnkey and fully automated labeling
■ One drum processed and labeled every 30 seconds
■ Single operator for multiple stations and huge labor savings
■ No need for preprinted label inventory
■ Changeable label designs on the fly
■ Nearly zero waste with on-demand print-and-apply application
■ Automated drum handling for improved employee safety
■ Flexibility for a wide variety of drum types

The Problem

A leading oil company was looking for a custom solution to automate its processing and labeling of 55-gallon drums, reduce labor costs, and improve product quality.

Previously, two pre-printed 5” x 5” NFPA labels were applied by hand to the lid and body of the drum, and a larger, preprinted 8.5” x 22” GHS-compliant label was hand-applied around the body of the drum. To replace this cumbersome, labor-intensive process and ensure consistent, high-quality labeling, the company needed an ideal solution that would eliminate label preprint-ing, reduce label inventory requirements, and eliminate the excess labor required to hand-apply labels.

One of the biggest challenges was that the company processed both plastic and steel drums of varying heights, diameters, and shapes. Any automated system would need to apply labels at various heights on the drum, depending on the drum being processed. A total of four turnkey stations would be needed, including two “left-hand” and two “right-hand” stations, and all systems needed to be flexible enough to process any drum configuration.

Adding complexity was the fact that the larger 8.5” x 22” label wraps around a significant portion of each drum’s body, so the drum must be captured and spun during the process. Moreover, the NFPA label must be applied opposite the larger label, on the same panel, which requires that each label application be controllable and coordinated for proper application.

The Solution

LabelMill, a leading label solutions developer for over 30 years, worked closely with the company and Zebra Technologies to create custom, turnkey labeling stations to meet every requirement. Four stations were built, including two “left-hand” and two “right-hand” stations, each with the following components:

■ 10’ roller bed conveyor mounted on a single, powder-coated steel frame with adjustable-height label applicator mounts
■ Pneumatic product stop gates with integrated input/output (I/O) to the company’s programmable logic controller (PLC)
■ (2) LabelMill LM3510 automatic print-and-apply label applicators with Zebra ZE500 thermal transfer printers (6” wide, 203 dpi printing)
■ Custom-built “trap-and-wrap” station for spinning the 55-gallon drum
■ LabelMill LM1510 servo drive wipe-on label applicator, 8.5” wide, loose-looped with GHS-compliant full-color printer (color print-and-apply system)
■ Powered unwind station with splicing table, custom controls, and turn bar for color printer
■ Centralized, touchscreen master interface to control all label applicators, the conveyor, trap-and-wrap station, and other system features
■ Safety light curtains with e-stop functionality to protect workers

New Process

Empty drums now arrive on a truck and are automatically loaded onto one of four staging conveyors by a robot. Product gates release a drum into each labeling station when signaled that it’s ready.

After the three labels are applied to each drum, the system releases the drum onto existing product conveyors and signals that it’s ready for the next drum. Drums are filled after the labeling process and loaded onto another truck for transport.

About LabelMill and Zebra Technologies

LabelMill has been developing labeling automation systems for over 30 years. We deliver standard and custom systems that solve the toughest labeling challenges and help you label products, materials, and packaging with maximum efficiency and cost savings. Combining decades of knowledge and experience with industry-leading print engines from Zebra Technologies, we design and build systems with the performance and flexibility to handle virtually any labeling application.