Linear unit for labeling foam
The investor produces and processes polyurethane foam for use in the automotive, furniture, cleaning, construction, and footwear industries. For their production line, we developed a dedicated linear unit for labeling foam with an "IN-LINE" solution. The device enables fast, accurate, and flexible label application under various conditions and includes a manually adjustable positioning system.
Initial challenge - The client sought a solution for reliable foam labeling with labels directly during production line operation. Existing methods did not allow sufficiently accurate application and there was limited space, as well as a need for flexibility regarding label height and position.
Result - We developed a compact linear unit with two-axis movement that allows manual adjustable positioning of the applicator along the X-axis and automatic movement along the Y-axis. The system ensures precise labeling even while the foam moves across the entire width of the production line. The linear unit is controlled by a Siemens PLC and features an HMI for unit management.
Solution description
In collaboration with the client, we developed a dedicated linear unit integrated into the existing foam processing line. The system is based on guide rails, ball screws, and servo motors, enabling stable and precise vertical movement of the applicator (Y-axis), while the horizontal movement (X-axis) is manual with fine adjustment capability.
The unit’s label applicator automatically prints and applies labels to the foam during the process. The application height and labeling frequency are controlled centrally by the main line controller, while the operator manually sets the labeling position.
The system includes an applicator position monitoring system, a safety lift in case of contact with larger foam pieces, ERP system connectivity, and integration with existing line control.
Linear unit for foam label application
Benefits for the client:
- accurate and repeatable labeling during production,
- minimal manual intervention — only the application position is set manually, everything else is automatic,
- easy adjustment of labeling width with fine tuning,
- reduced error risk thanks to integrated sensors and safety mechanisms,
- integration into the existing line without major modifications.
Packaging and industrial labeling solutions
The linear foam labeling unit is just one of many solutions we have developed to optimize labeling and tracking processes.
See more examples of devices we designed for the packaging and labeling industry.
Operation steps
1. Manual positioning of the applicator — The operator uses the guide brake to manually position the applicator along the X-axis at the desired labeling spot.
2. Automatic height adjustment — The system automatically sets the application height based on data from the main line controller and an optical measuring sensor (Y-axis).
3. Detection of correct applicator position — A sensor checks if the applicator is correctly positioned. In case of interference, a safety lift is activated.
4. Printing and label application — The labeler prints and applies the label directly onto the foam joint during processing.
5. Continuation of the line process — The labeled foam continues to be transported smoothly along the line.
Labeling applicator for foam seams