Brady GlobalMak - Review

Before I conclude this month’s discussion about labeling, there is one more machine I should talk about. In it’s features and capabilities this machine is so far ahead of all others that it deserves recognition.

If you need a labeling powerhouse, the Brady Globalmark is the machine for you. It is available in three models:

Monchrome - prints one color on a different color tapes.

Multicolor – prints in one color, multiple spot colors, and full process color on a different color tapes.

Color & Cut – has the color printing features of the Multicolor model, but also includes the ability to cut labels and signs in custom shapes (or make cut vinyl lettering and graphics).

The supplies available for the GlobalMark cover just about every labeling need, except those that require highly specialized materials--such as required for laboratory and aircraft cable labeling.

Indoor/Outdoor Vinyl: The GlobalMark indoor/outdoor vinyl tapes come in nine colrs and widths ranging from ½” to 4 inches. They have an average 5+ year outdoor durability. The may be applied at temperaturesas low as 0 degrees F and will adhere well to pipes, walls, equipment, windows and most other clean dry surfaces.

Polyester tapes are available in eleven colors. These tapes have a low halide content and are designed for labeling stainless steel pipes and surfaces. The ultra-smooth finish of polyester tape means they are excellent for making signs by mounting to them on rigid panels and for labels applied to very smooth surfaces.

A variety of specialized labeling materials are available for the GlobalMark. These include tag stock material, repositionable vinyl tapes (two colors), metallized poyester tape, static cling tape, non-adhesive magnetic backed tape (two colors), reflective tape (two colors), glow-in-the-dark phosphorescent tape, semirigid brushed gold material, cold temperature tapes (two colors), and die-cut RTK labels.

The GlobalMark is a stand-alone desktop machine that includes a full-size keyboad and large LCD screen. On the color versions of the GlobalMark the screen provides a touch-screen interface making designing and printing labels even easier and faster. The GlobalMark can also be connected to your PC, and can print labels, signs, graphics and photographs stored on your computer.

Changing tapes and ribbons is simple. The top of the GlobalMark snaps open providing a large access area. Being a large guy with big hands I appreciate the room and easy access the GlobalMark provides for changing tapes and ribbons. Tape cartridges can easily be inserted and locked into place in the bottom of the machine. Self-contained ribbon cartridges quickly snap into place on the underside of the cover.

The hundreds of built-in templates included with the GlobalMark are a great time saver. The templates cover six common industrial applications: signs, pipe markers, right-to-know labels (NFPA Diamond and Color Bar formats), tags, equipment identification, and warehouse identification. You can also add your own custom templates, meaning a custom label or sign only needs to be designed one time.

When you have a variety of different labeling and sign making jobs, be sure to take a look at the Brady GlobalMark. It has more features and capabilities than you’ll find in any other label and sign printer.

Proper Container Labeling

Containers holding hazardous chemicals fall into three categories:

Primary Container - this is the original container from the manufacturer. The manufacturer is responsible for the labeling on his container.

Secondary Container - these are smaller containers used to store and use chemicals. These could be plastic jugs, spray bottles, old coffee cans or drums. Secondary containers must be labeled to identify their contents and the labels must include appropriate hazard warnings. The NFPA diamond is often used on labels for secondary containers.

The purpose of labeling secondary containers is so employees, visitors, contactors and outside emergency response personnel can quickly identify the hazard level of the material in the container. This is particularly important for emergency response personnel as they may need to quickly decide how to approach and deal with a container in an emergency situation. For this reason is is important to use a standard system, such as the NFPA diamond, to mark secondary containers.

Portable Container - these are containers used to transfer hazardous chemicals between labeled containers. They are intended only for the immediate use of the employee who performs the transfer. They may not be left unattended and they must be cleaned after each use. Portable containers are not required to have labeling -- however you may wish to label them so that each portable container has only a specific, designated use.

Pipe Markers Improve Safety & Productivity

Pipe markers are labels used on piping systems to identify the contents of the pipe, the direction of flow, and whether or not the contents are hazardous. Pipe markers are used everywhere from apartment buildings to paper mills.

What is a pipe? The ASME/ANSI code defines a pipe as "conduits for the transport of gases, liquids, semi-liquids or fine particulate dust."

How do pipe markers improve safety and productivity? By putting needed information directly at the point of need. For example, unmarked pipes are particularly dangerous when outside services are responding to an emergency. Proper labeling of pipes saves time by showing employees and contractors exactly where they are in the system--they don't need to spend time looking through drawings and reference materials. They also help prevent operational errors and guide service staff in tracing through systems to identify problems.

There are three pipe marking standards are most commonly used. The ASME/ANSI standard is the most widely used guideline. Although ASME and ANSI are separate organizations, they’ve agreed to publish the same pipe marking standard and to identify that standard as A13.1-1996.

A second standard is the NFPA (National Fire rotection Association) 99C-1996 / CGA (Compressed Gas Association) C-9-1988. This standard has guidelines for marking piping containing compressed gas and are most commonly used for medical gas piping.

The third standard is published by IIAR (International Institute of Ammonia Refrigeration) and is used for marking piping and components used in ammonia systems.

The purpose of the ASME/ANSI standard is defined as to “assist in identification of hazardous materials conveyed in piping systems and their hazards when released into the environment.” This standard recommends the size of the lettering on the label and the length of the background color field for various pipe diameters. It also recommends label locations. The objective is to have markers that are “located so that they are readily visible to plant personnel from the point of normal approach.”

You can find out more about the ASME/ANSI pipe marking standards in this online pipe markling tutorial.

The NFPA/CGA standard specifies the label location and color coding to be used for compressed gas systems. It also recommends that the label identify the gas and the operating pressure of the piping system.

The IIAR labeling guidelines deal with the special requirements of labeling ammonia systems. In addition to specifying size, color and location of labels, the IIAR system incorporates standard abbreviations that identify the physical state of the ammonia, the pressure and the specific location within the ammonia system. For example, “LIQ” identifies the contents of the pipe as being liquid, and “LTS” identifies the location as the “Low Temperature Suction”.

Information about the IIAR pipe marking guidelines.

Brady ID Pal - Review

Let’s take a step down in size and look at the 1-1/4 pound (including batteries and label tape) Brady ID Pal thermal transfer label printer. This is one of the smallest, lightest industrial label printers available.

The first thing that strikes me is that the ID Pal is promoted as “designed to be carried in a tool box”. That would be convenient, but a problem I’ve experienced with other electrical devices is that sometimes they get turned on accidentally as they are jostled in my toolbox, resulting in the batteries going dead. On the ID Pal the power button is located next to the LCD screen. A raised edge around the LCD screen protects the screen and, combined with the curved shape of the ID Pal, provides protection for the power button. While it is possible for the ID Pal get turned on accidentally, it does not appear this is likely to happen. And, if it should get turned on, the ID Pal will automatically shut off after about five minutes.

Overall Brady has come up with an excellent ergonomic design for the ID Pal. Its curved shape comfortably fits in either hand, and the ABC style keyboard is easy-to-use. For fumble fingered people such as me, it is nice to see in the specifications that it has been dropped tested in a four foot drop onto concrete.

Three types of supplies are available for the ID Pal: nylon cloth, polyester and vinyl tapes. They are available in three widths, 3/8, ½ and 3/4 inch.

The nylon cloth tape is only available in black printing on a white tape. It is intended to be used for labeling wires, cables and for use on highly textured surfaces.

The polyester tape is available with black printing on a white tape or on a clear tape. Polyester tapes are intended for use on smooth, flat surfaces.

The vinyl tape is available with black printing on six different colors of tape. Vinyl labels are for use on wires, cables, textured surfaces and for general labeling.

With a built-in library of common electrical and datacomm symbols, and preset label lengths for printing wire markers, the ID Pal has been designed with computer network, telecommunications, and other electrical installation and maintenance applications in mind. In addition, instrument technicians, laboratory workers, audio/video engineers and other users of small labels will find this machine handy to have around. The only drawback I can see is that it does not print bar codes.

Kroy 5100 Labeler - Review

Let’s now go from the large Brady PowerMark, to the small Kroy 5100. This handheld labeler is designed with electrical installations in mind, although it can take on standard labels with it up to one inch polyester tapes.

This appears to be a hot machine right now. Although Kroy gives a list price of $399 on their web site, the lowest price I could find on the web was $430, and it was sold out everywhere I looked.

The Kroy k5100 is a Direct Thermal (DT) / Thermal Transfer printer that has a print resolution of 300 dpi. This provides fine detailed printing that is excellent even for small bar codes.

Supplies for the 5100 come in 1/2”, 0.8” and 1 inch tape widths. Supplies include:

Self-Laminating Wire Wraps – wires and cable

Polyolefin Shrink Tubing – wire labels

Polyester Industrial Labels – general labeling

Laminated Labels – provides greater durability

Tamper Evident Labels – label breaks up leaving a residue if someone attempts to remove it

Cast Vinyl – general labeling that conforms well to corners and bends

Die Cut Labels – for terminal blocks and components

The K5100 is a continuation of the K2000 series and it uses the same supplies as the K2000, K2500, K3000 and K4100. Although in the past Kroy has had problems maintaining an adequate inventory of supplies, with the increased number of printers in user’s hands, hopefully they’ll ramp up manufacturing to better meet demand. However, when purchasing the Kroy 5100 it’s a good idea to be purchasing from a dealer who stocks a significant inventory of Kroy supplies instead of relying on Kroy to have supplies available.

Some of the improvements over previous models include auto sizing, increased print speeds, internal battery charger, downloadable fonts and increased on-board memory.

While larger than some of the handhelds from Brady, the K4100 easily fits in your hand. It’s ABC keyboard is well-spaced and easy to use. Tape cartridges fit into the top of the machine and can quickly be changed with one hand. Overall the Kroy K5100 is an excellent value.

It would be handy to have a belt mounted or shoulder carrying case for the K5100. While not available from Kroy, Graphic Products offers a free K5100 carrying case/holster when you purchase a minimum amount of supplies with a K5100. This is a deal worth considering.

Brady PowerMark - Review

To start our look at specific label printers I've selected the Brady PowerMark. This is a large format, heavy-duty, thermal, color label and sign printer. The PowerMark is a machine designed for the big labeling jobs in a variety of ways.

PowerMark Supplies - The PowerMark has a good range of supplies available.

The most frequently used supply will be indoor/outdoor grade vinyl. The PowerMark vinyl tapes adhere well to pipes, walls, windows--most clean dry surfaces. The conform well to curved, rough and irregular surfaces. PowerMark vinyl labels are resistent to grease, oil and most industrial chemicals. They have an average five year outdoor life and are available in 11 colors, plus clear.

Low halide polyester tape is available in three colors plus clear. This ultra smooth outdoor grade material is used to labeling stainless steel and nickel surfaces. A typically application would be for making signs that use stainless steel sign panels.

Other specialized supplies available for the PowerMark include reflect tapes, glow-in-the-dark tapes and tag stock.

PowerMark ribbons are available in eight monochrome colors, as well as for two color and four color printing.

Tapes and ribbns are available in widths from 4 inches up to 10 inches.

PowerMark Printer

The PowerMark machine has a heavy duty design that is capable of producing a high volume of labels on adaily basis. It's full-size QWERTY keyboard and large, tilting LCD screen make creating labels and signs easy.

Loading ribbons and tapes is simplified by the easy access to the interior of the PowerMark. The entire top and right-side of the machine lift up, providing plenty of room for ribbon cartridges to be easily installed. Rolls of tape can be quickly put into place and threaded through the tape feed slot.

The PowerMark includes a number of built-in applications that include standard signs, hazardous waste labels, and pipe markers. In addition, custom labels can be stored in the PowerMark's memory.

Printing is crisp and clear. It is resistant to scratches and abrasion.

Overall this is an excellent machine for those who need larger labels, or large numbers of labels.

Kaizen Workcells and Taki Time

Workcells are the foundation of Kaizen and Lean Manufacturing. A workcell is a small, compact arrangement that includes more than a single machine or workstation. It is a self-contained unit for manufacturing a product, or highly similar products or components. The small physical size of a workcell—typically fewer than 15 machines-- facilitates product movement and communication. Workers within a workcell are usually cross-trained so they can work in several areas within the cell.

Typically the machines in a workcell are arranged in a U-shape. It is typically self-contained, having available all of the resources needed to manufacture a product or component. Machines are arranged in the sequence needed for manufacturing the product or component, so the work-in-progress can flow smoothly from machine to machine. Communication within a workcell is simple since every worker has a common mission and is physically close to others in the workcell.

Balancing Work Flow – Takt Time

“Takt” is the German word for the baton used by an orchestra conductor to set the beat, or the speed of the music. Toyota picked up this word and used it in the Toyota Production System (TPS) as a result of German assistance to the Japanese aircraft industry during World War II. In TPS the term Takt Time is the amount of time it takes to finish one unit of production. He is an example that has been greatly simplified:

If your company makes bicycles, then the amount of time it takes to make one bicycle is the Takt time for bicycles.

Let’s say that your factory makes one bicycle every two minutes. That means the Taki time is two minutes.

Each bicycle has one seat. So the workcell that makes seats must produce one seat every two minutes. That workcell also has a Taki time of two minutes.

Each bicycle has two wheels. That means the Taki time for wheels is one minute. The wheel workcell must produce one wheel every minute.

Each wheel has 24 spokes. To match the wheel production rate the spoke workcell must produce 24 spokes per minute, giving a Taki time for spokes of 2.5 seconds.

How is the Taki Time Determined?

Taki time is set by customer demand. If you receive orders for 240 bicycles per day, that gives a Taki time of two minutes per bicycle (240 divided by 8 hours per day means 30 bicycles per hour are needed).

If demand increases to 480 bicyles per day, the Taki time is reduced to one minute per bicycle. This reduction in Taki time flows throughout the bicycle production process such that the Taki time for wheels is now 30 seconds, and the Taki time for spokes is now 1.25 seconds. Of course, your staffing and resources will need to be adjusted to match the new Taki time. The purpose of Taki time is to keep the workcells in balance, based on the need for bicycles. Thus this is a “pull” system. Each workcell produces the quanity that is required by the next workcell in the production process, based on the demand for the final product.

Immediate Results From Kaizen

A new article available online describes how a Kaizen mindset, and a quick walk through a manufacturing facility, can result in major cost savings. Tom Dossenbach, the author of the article, points out:

"The norm in industry today is to repair the damage or to remove the symptom. That’s what they were doing. The Kaizen way is to get to the cause and remove it, permanently. Putting it another way, we often are satisfied to say: 'If it’s broken, fix it.' In a plant practicing continuous improvement, the question is: 'Why did it break?'"

Purchasing A Label Printer

If you already have a label printer that needs to be replaced, you probably have a good idea of what you need. You'll be familiar with the types of labels you use, your labeling volume, and your requirements for label printer features. Your decision involves finding the new machine that meets your current requirements.

For those who do not currently own a label printer, you'll need to start by collecting some information. (Online article about purchasing a label printer). First, how are you currently doing your labeling? How well is what you are doing working? What problems have you had with labeling in the past? For example, if you've used labels produced by an inkjet printer, and had the printing smear or wash off, then you'll need to consider a termal transfer printer instead of a dot matrix label printer.

Have your existing labels been durable? Do they stay stuck?

What needs to be labeled that has not been labeled? Under what environmental conditions will the labels be applied? What environmental conditions must the labels survive? Heat, cold, water, chemicals, abrasion, etc. What size labels do you need? Do your labels need to be color coded? If so, do you need just the tape (background) to be in various colors, or does the printing also need to be in various colors? What colors do you need?

These types of questions will help you determine the types of label materials you'll need and the best printing method to use. The greatest limiting factor for most label printers is the type of supplies available. By knowing what you need your labels to do, you can select a machine that has the supplies you'll need.

How many labels do you expect to need to print each day? A light duty machine can typically handle up to 100 labels a day. If you'll need to print more than 500 labels a day, then you'll need a heavy duty machine.

You also need to consider how quickly you need to print labels, and how frequently during the day labels will need to be printed. These are factors to take into consideration when looking at machine print speed, and when considering whether to purchase one or two machines.

In some cases you may not be able to get a single machine that can do everything you need. It is not uncommon to purchase a heavy-duty desktop printer that remains in one location and handles the bulk of the label printing, and a lightweight, specialized, handheld labeler that can be easily carried wherever it is needed in your facility.

Finally, what features do you need your label printer to have? Does it need to be able to print special symbols? Do you need to use it with a computer database? What type fonts do you need? What languages do you need to use? Does it need to be able to draw boxes and frames?

Once you've compiled all this information, start looking at label printers and supplies. Don't be surprised if you find additional criteria you want in your supplies or printer.

Some of the better brands of label printers to look at include: Brady, K-Sun and Kroy.

Label Materials And Adhesives

Label tapes are available in a variety of colors and widths. Aty first glance it apears we just need to pick the color and width we want, and we're good to go. But there is a lot more to labeling supplies than what meets the eye.

There are hundreds of combinations of "tape" material and adhesive backing. For example there are paper, polyester, cloth and vinyl tapes. There are permanent and removable adhesives. There are adhesives that adhere to rough surfaces and adhesives that stay stuck at low temperatures. Which type of tape and adhesive you choose depends on what needs to be labeled and the environmental conditions the label will need to withstand.

The purpose of this article is to introduce you to some of the more specialized types of label materials. We all know there are labels that work well on file drawers and other clean, dry surfaces. But what happens when you need to put a label on a textured wall or oily pipe? How about labels for laboratory tools that are subject to nitrogen baths, and what about labels you need to see when there is a power failure and the lights go out?

Polyvinyl chloride (PVC), or just "vinyl" label tapes are available in two basic types of vinyl. Calendered and high performance, which is sometimes called "cast vinyl". The difference between them is in how they are manufactured. Calendered vinyls are made by running the vinyl between rollers to flatten it into a sheet. Cast vinyls are made by by a process that is more like pouring paint onto a flat sheet of paper and allowing it to dry into a thin, smooth sheet.

Calendered vinyls cost less to make and lend themselves to large production runs. They are excellent for most labeling applications since most labeling applications involve flat, smooth or gently curving surfaces. The problem with calendered vinyls is that the rolling process builds stress into the vinyl. This stress tends to cause a small amount of shrinkage over time that results in labels that do not adhere well to objects with tight corners, bumps, rough surfaces or troughs.

The process used to make cast vinyl does not result in stress in the vinyl. Thus cast vinyl will remain tightly adhered in corners, over bumps, on rough surfaces and in troughs. This is why it is called a high performance vinyl. The drawback of cast vinyl is that it costs significantly more.

If you need to label oily or greasy pipes, the best option is to use strap-on or wrap-around labels. Instead of using adhesive, these labels are mechanically attached to the pipe. If you have hot pipes, up to 1000 degrees (F), then porcelain enamel strap-on labels are an option.

When it comes to laboratory labeling labels are needed that can withstand both the high temperatures of an autoclave, and extreme low temperatures of a nitrogen bath. Laboratory labels are made from materials such as nylon cloth, polyester, polypropylene and vinyl. Polyester labels are available that can withstand autoclave temperatures up to 260(F) and some nylon cloth labels are suitable for temperatures as low as -320(F). In some cases, such as labeling test tubes, the thickness of the label is important. Standard labels would prevent test tubes from being inserted into test tube racks. Very thin, low profile, vinyl and polyester materials are available that have a minimum impact on the diameter of the test tube. The specific material you select will depend on the temperature range, resistence to solvents, flexibility and label thickness requirements.

Other types of specialty label materials include glow-in-the-dark materials. These labels will glow allowing them to bee seen and read in the dark. Tamper proof materials are available for labeling tools and equipment in a way that leaves evidence if the the label is tampered with. There are repositionable labels that use an adhesive that allows them to be removed and reapplied in another location.

Just as there are many types of label materials, there are also a variety of label adhesives. Thick, "gummy" adhesives are used on labels intended for use on textured surfaces. There are chemical resistant adhesives, low temperature adhesives and even labels that do not have adhesives such as static cling and magnetic-backed label materials.

When purchasing a new label printer it is important to select a printer that can use the types of labeling materials you know you'll need. While some printers have a wide variety of label materials available, while others are more specialized and can use a limited selection of label types.

Communicating With Labels - Print Methods

There are two types of print methods used by label printers, impact printing and thermal printing.

Impact label printers are usually dot matrix type printers. This type of printer uses a "matrix" of small wires which impact on a ribbon to transfer an image to the label tape. Dot matrix label printers are typically the lowest price in their size range. They print on paper and produce a medium quality image. They are not suitable for printing fine text or images, and dot matrix labels will not stand up to outdoor weather.

Dot matrix labels are typically used for short term applications or for labels that are not subjected to significant handling. Examples would be labeling in-progress work, marking temporary wires and cables, and making shipping labels.

Thermal labels are created using heat to create the image. There are two types of thermal labels: direct thermal and thermal transfer printing.

With direct thermal printing the print head applies heat directly to a paper tape to produce an image. We most commonly see this type of printing in cash register receipts. The paper tape usually has a flimsy, slick feel to it. Direct thermal labels are low cost, however they are not durable and will quickly fade in sunlight or warm locations. They are best used for temporary labeling applications.

Thermal transfer printing heats a ribbon which then transfers the ink to the label tape. Thermaal transfer printing can produce detailed images and very small text. It can print on a variety of materials, including paper and indoor/outdoor grade vinyls. And thermal transfer printing is durable. The cost of thermal transfer labels varies based on the ribbon and label materials used.

A wide variety of materials are available for thermal transfer printing. They range from paper tapes and die-cut paper labels, to outdoor grade vinyl tapes, to specialized materials such as chemical resistant, glow-in-the-dark, and low temperature materials.

In many cases the same printer can be used to make both direct thermal and thermal transfer labels. Both printing methods use the same print head.

Because of its quality, durability, and flexibility, thermal transfer printing is the most popular label printing method for both home and business uses. Direct thermal and dot matrix label printers are generally limited to specialized applications.

Free Kanban Guide

A free guide to Kanban just became available. It can be ordered online at:

http://www.graphicproducts.com/free-gifts/kanban-guide.php

Communicating With Labels

This month I'll be discussing a subject that does not get much attention, labeling. Labels are everywhere, but unless they are required by law, we don't pay much attention to them. However, proper labeling improves communication with the result that productivity is improved, safety is improved, and the information employees/visitors need is available at the point of need.

I'll be start by discussing label printer technologies and their applications. That will be followed by a series of posting about labeling materials -- the tapes and die cut materials labels are printed on. For the remainder of the month I'll review a specific machine each day.

Why is good labeling important? Because it puts information at the point of need. Whether it's safety, maintenance, or operating information; directional information or security information; whether the labels are wire markers, bar codes on tools, or vehicle identification labels; good labeling means that whatever information is needed will be available at the point of need. This results in benefits such as eliminating time wasted searching for information, eliminating confusion, and reducing the potential for errors and accidents. This means there is less wasted manpower and material, there is reduced equipment downtime, and productivity increases.

I hope this series helps you improve communications through labeling.