2D codes can hold significantly more data, enabling packaging to transport an unprecedented range of (multilingual) information about a product. Second, the twodimensional codes are more reliable. In most cases, they are still readable even if they get damaged or smudged. Finally, they offer greater flexibility for data communication. For instance, they make it possible for consumers to interact with product packaging.
New High-performance Camera
However, the new 2D codes put new demands on the equipment used to monitor product mix-ups, which is essential for pharmaceuticals and foodstuffs: In fast-running folder-gluers, only high-performance matrix cameras are capable of reading 2D codes reliably and without compromising on speed. Baumer hhs has developed a special system for monitoring product mix-ups that meets this requirement: the Xcheck Scan 2D. As a leading manufacturer of industrial gluing and quality assurance solutions, the Germanbased company has consistently been an industry pioneer over the decades. Its new Xcheck Scan 2D system for monitoring product mix-ups upholds this tradition. “The Xcheck Scan 2D reliably reads 2D codes on every single package, even on the fastest folder-gluers currently available on the market, in other words at speeds of some 600m/min.
All machine operators have to do after each job changeover is train the system by having the camera read one code,” says Ralf Scharf, Folding Carton Business Development Manager, Baumer hhs. Another component developed specifically for this application is the continuous illumination, which further supports reliable 2D code reading and eliminates the need for flash lamps. The matrix camera is operated via Baumer hhs’s Xtend3 controller, known in the industry for its exceptional ease-of-use. It analyses codes and compares them with specified standards in just fractions of a second. If wrong cartons are identified, the Xtend3 automatically initiates their ejection from the process. In other words, the new camera system guarantees production runs with no product mix-ups.
Simple Exchange
On folder-gluers, blanks usually are checked for any mix-ups by sensors at the pre-breaker. The machines maintain very tight tolerances in this area to guide the glue flaps. The distance here between the sensors and the glue flaps is constant, and the precision guidance prevents any vibration or fluttering of the flaps. All of these aspects make for reliable code reading. For example, the Pharmacode, a one-dimensional barcode with up to 16 bars of various thickness that is traditionally printed on the glue flaps of folding cartons in the pharmaceuticals industry, is also read by a sensor usually positioned at the pre-breaker. But sensors are not suitable for monitoring product mix-ups using 2D codes. Even the camera systems currently available are not powerful enough to read these codes. As a result, folding carton manufacturers are being forced to run their folder-gluers at slower speeds if they are already printing packaging with 2D codes and have to check for product mix-ups. In this case, they can no longer take full advantage of their potential productivity. Thanks to the new matrix camera developed by Baumer hhs, these manufacturers no longer have to put up with such restrictions.
Facilitates Handling
Apart from their higher information density and greater flexibility in virtually all applications, 2D codes offer even more advantages in folding carton production: whereas the Pharmacode today has to be added manually during prepress, 2D codes can be incorporated in a packaging design automatically. Automating this step increases efficiency while ruling out a source of error. Yet another aspect: 2D codes are of compact size and therefore easier to integrate in a packaging design, which can be a major advantage especially on small folding cartons. Data matrix and QR codes can store up to 7,000 characters, for example, for instruction leaflets, nutrition facts, allergen information, proof of origin labels or sustainability information. They can also be used to print variable data on packaging, such as expiration dates or batch information, making the packaging easier to track and trace. “In view of the significance of GS1 Global, we can assume that the Sunrise 2027 initiative is going to be a success. This assumption is further backed by a statement published in late June 2024 by some 30 brand-name manufacturers such as Master Kong, Mondelez, Nestlé, Procter & Gamble, The J.M. Smucker Company and Tsingtao, as well as retailers such as Alibaba, Lidl and 7-Eleven, announcing their support of the transition to 2D codes with GS1 standards,” explains Scharf.
Easy to Retrofit
The new camera system from Baumer hhs for monitoring product mix-ups can be integrated in folder-gluers in the same place as current equipment, meaning only minimal time and effort are required for retrofits. Many folding carton manufacturers presumably will work with both sensors and innovative cameras like the Xcheck Scan 2D for the time being. Baumer hhs now offers them both options. Packaging manufacturer La Grafica SRL, based in Ciserano, Italy, is already using the new system successfully in a field test at a speed of 450m/min.