A Study on the Impact of a Glue-Based Labeling Machine Using an Infrared Sensor

Abstract

The packaging labeling process in the canned food industry faces instability and production waste, such as folded or misaligned labels, caused by the lack of precision in traditional open-loop control systems. This research investigates the effect of infrared sensor installation angles on the efficiency and stability of the can labeling process in an actual production line. Statistical Process Control (SPC) techniques were applied to analyze process variation and assess production system performance. The experiment compared a conventional labeling machine with an improved prototype equipped with infrared sensors installed at angles of 35°, 25°, and 15°. Each condition was conducted four times under identical operating conditions in the actual production environment. The number of correctly labeled cans was analyzed using descriptive statistics, including mean and standard deviation, to evaluate process efficiency and consistency. The results confirmed that the 15-degree installation angle achieved the highest efficiency, reducing the total waste rate to 1.67%. In contrast, the original system without optimized angle control exhibited a waste rate of 82.11%. Specifically, label misalignment dropped from 45.20% to 0.83%, and wrinkled labels decreased from 36.91% to 0.84%. This improvement significantly enhanced the accuracy of identifying the initial labeling position (Home Position) and minimized signal interference caused by specular reflections from metal surfaces. Consequently, the production process attained higher stability and reduced material loss costs in the packaging industry.