In the modern world of manufacturing speed is one of the most critical elements of competitive advantage. Not only must the product be produced, but also the information processed on it must proceed with the same speed and accuracy. Coding—the processing of products with dates, lot numbers, barcodes, or QR codes—directly impacts the speed of the production line.
Even the slightest delay in the coding process can cause an entire line to stop or reduce productivity. Therefore, increasing coding speed is not just a technical choice for manufacturers, but also a strategic imperative.
Factors Affecting Coding Speed
- Line Speed: The flow rate of products on the conveyor.
- Ink Drying Time: It is the most important determinant of speed, especially in inkjet printers.
- Hardware Capability of the Device: Print head resolution, frequency and processing capacity.
- Complexity of the Code: Detailed signs such as QR codes and DataMatrix require more processing power.
- Environmental Conditions: Humidity, temperature, dust and airflow affect drying time and print quality.
Practical Ways to Increase Coding Speed
1. Choosing the Right Coding Technology
Each sector has different needs.
- Inkjet printers are suitable for flexible production at high speed.
- Laser marking stands out in applications that require permanent and high resolution.
- Thermal transfer is a high-resolution option for packaging films.
2. Ink and Consumable Optimization
- Using fast-drying inks reduces downtime.
- Choosing the right ink for the packaging surface prevents reprints.
- When the consumable quality is low, drying time is extended and speed is lost.
3. Automation Integration
- an encoder to synchronize the printer with the line speed.
- Ensure the printing is triggered at the right time with photocell adjustment
- Integrate automation systems and the coding device into the production line's ERP/MES software.
4. Regular Maintenance and Cleaning
Clogged nozzles or lens contamination will cause the device to slow down.
- Create regular maintenance plans.
- Use automatic cleaning functions actively.
- Predict potential failures with predictive maintenance applications.
5. Optimizing Code Design
- Avoid unnecessarily long texts.
- Optimize QR and DataMatrix codes to maintain scannability but avoid unnecessary density.
- When choosing fonts and points, focus on settings that will increase readability while reducing processing time.
6. Strengthening Operator Training
Trained operators can use the device's full capacity.
- Correct interpretation of error messages prevents speed loss.
- In case of simple problems, rapid intervention of operators maintains the continuity of the line.
7. Setting Up a Dual Coding Station
For high-volume production, installing a second coding station is an effective solution for speed and continuity. Even if one is down, production won't be interrupted.
Sectoral Examples
Food sector
A dairy producer increased coding speed on its production line by 25% thanks to the integration of fast-drying ink and encoder.
Pharmaceutical sector
A pharmaceutical company switched to a laser marking system, ensuring speed and durability on blister packs.
Automotive
A spare parts manufacturer reduced coding time by 15% by optimizing its QR code design.
KPIs to Measure in Coding Speed
- First Time Pass Rate (FPY): The rate at which the code is printed successfully on the first try without any errors.
- Production Capacity: Number of products coded per hour.
- Downtime: Total downtime per week.
- Ink Consumption: Cost per thousand prints.
Frequently Asked Questions (FAQ)
1. How can inkjet printers increase speed?
Speed can be increased through encoder and photocell synchronization, fast-drying ink, and regular maintenance.
2. Is laser marking effective at high speeds?
Yes. Especially for serial numbers and QR codes, the laser works seamlessly even at high speeds.
3. Does complexity of code slow down speed?
Yes. More complex code requires more processing power, so design optimization is important.
4. Does increasing coding speed increase costs?
When the right technology is chosen, costs don't increase; on the contrary, total costs decrease because the waste rate decreases.
Coding speed on production lines is a critical factor that directly impacts a business's competitiveness. With the right technology selection, ink optimization, maintenance practices, and trained personnel, coding processes can be made both faster and more reliable.
Electrojet Technology offers professional solutions that accelerate and uninterrupt coding in production lines with laser and inkjet solutions.
