Positioned side-by-side, ProLabel’s two VSR300 inspection slitter/rewinders have replaced several units from another supplier.

To increase production speed and efficiency, two Mark Andy VSR300 label-inspection slitter/rewinders—one 13-in. and one 17-in.—have replaced several units from another supplier. A third 17-in. VSR300 will be coming on board soon to address film packaging as ProLabel begins to target the flexible-packaging market.

“[The VSR] is more user-friendly, easier to set up and runs all the time when compared to the older equipment which needed tweaking and a number of changes during production.” In addition to quick setup and operator friendliness, ergonomics were also a design priority for the VSR product line, the supplier says.

Carty adds, “With fewer people, it's simpler to train on this equipment. We unwind on the left and rewind on the right, so it's easier to see and easier to web. It's a solid machine and runs faster. As far as operator interface, our previous equipment had a one-line digital display to scroll through, which required extensive training . The Mark Andy VSR has a convenient touchscreen offering more convenience and less training. Last week I brought someone into the rewind department and trained them in less than a day, whereas, in the past, it could take a week or two to train an operator. Operators can now spend valuable time on the actual job rather than on machine adjustment.”

Pressure-sensitive labels are inspected on the Mark Andy VSR300 system, which has a smaller footprint to free up valuable production-floor space.

The machines have a 4 x 8-ft footprint and stand 4 to 5 ft high, thus freeing up more space on the shop floor. “Workflow is more logical,” says Carty. “Less material is moved in a more efficient manner with the new system. There's a lot more intelligence in it.”

Some additional features of the VSR300 include an enhanced control system from Rockwell Automation and a waste wind-up complete with a counter. Carty recalls the old days when waste was pulled out manually, cut, and tossed on the floor, cluttering the workspace. Enhanced tension control has improved rewind roll quality as well. “I remember when we had a rubber mallet to smack components into place!”

“We're definitely investing in another VSR as we expand into the flexible packaging market. Prior to shipping the new unit, an operator and I will go to Mark Andy's demo facility to run material hands-on. The old equipment will be removed and when the new VSR arrives we expect to uncrate it, wire it, level it, and in a few hours, run it at speeds the former units couldn't reach—our new machines run at 900 fpm; the old ran at 700 fpm.”

For ProLabel, it's rewarding to do the math—11 presses, 70 employees, two shifts—factor in four years to a solution of seven presses, half the number of employees and one shift to equal undiminished revenue.