Trends in RFID Converting
The development of Radio Frequency Identification (RFID) and its application via narrow web converting is proving to be highly productive for those who approach it in the right way. Although not quite the Holy Grail that it seemed in the early nineties, RFID is now successfully used in many market niche applications, with commercial security applications playing a key role.
Because RFID conversion has yet to achieve everyday, high volume/low cost levels, a significant number of narrow web converters who have invested in RFID machines have failed to meet their profitability targets. This failure can be attributed partly to the RFID market not taking off in the way that was anticipated and partly to the shortcomings of the machinery.
Current Machinery
So far, there have been two types of RFID converting machines. The top level machines can handle both wet and dry inlay and the more basic, entry-level units are suitable for for wet inlays only. What they have in common is that they are specialist devices - they can produce RFID material only.
With low volume orders, the machinery becomes under-utilised, leading to high production costs and catastrophic Return on Investment.
Of course there are exceptions. But success has exposed another flaw in the majority of the RFID machines currently available. Because they are designed for very narrow webs (typically 100-150 mm), the machines do not provide their owners with the option of doubling or tripling output by running two or three labels or tickets across the web.
The future of RFID converting machinery
To counteract the abovementioned weaknesses in RFID converting and to make it a risk free machine investment in the future, the following criteria must be taken into account:
Multiple applications - The RFID converting machine must have the facility for additional options to enable other applications such as multi-layer and booklet labels, adhesive coating, industrial label and tape solutions etc. Also die-cutting and printing options must be available. This enables more production time with same machine, hence less investment risk and a better return on investment.
Upgradeability - While today’s RFID volume is still small, one across application is fine but once volumes increase, the RFID converting machine must have the options to extend to 2, 3 or even 4 across production. So it is important to take the web width of the machine into account today in order to avoid surprises tomorrow. Instead of just 100-120mm wide only, opt for 250, 330 or even 430mm width. It is also unwise to select a machine that can only handle wet inlays. Although it may be fine to start with, once the volume increases dry inlays may be more productive and cost effective. Make sure that your initial investment in a lower cost, wet inlay only machine can be upgraded to dry inlay using vacuum drum principles. Also examine any other options.
Servo technology for web tension and registration - Web tension control for different materials and web widths must be perfect to have any chance of achieving excellent insetting and auto registration accuracy with pre-printed reels of different type of materials. A totally servo driven machine is a must and half-way “mechanical drive with some servo” should be avoided.
Inspection and verification - As with any special application, zero tolerance is becoming the norm, hence inspection, verification and recording features are a must with such machine investments. Check the flexibility and capability to read the whole range of HF and UHF and maybe other applications.
Operator friendliness - Machine simplicity is key for day-to-day machine handling. The easier the web path with plenty of space between the modules, the better the production output and waste reduction will be. Also, if modifications or additional options are needed in the future, space will be available without making the operator’s job more difficult (and dangerous). Check also the length of the actual machine as well as the web path length from unwind to rewind, both important points regarding profitability and waste reduction.
Off-line vs in-line - Without question, off-line is the way forward by using a traditional printing press to print the reels at high speed and then transferring them onto the off-line converting press. Once volumes have reached the point where in-line can make sense, it is important that your off-line converting machine can be integrated into an existing or new printing press.
Diversification into new applications - by choosing a RFID converting machine concept that enables more then one application, doors will open for additional, added value, intelligent label and ticket solutions. (E.g. multi-layer labels and tickets require the same tension and insetting features as RFID insertion. If adhesive coating by hot melt, flexo or screen is used for RFID, then this technology can be used for other innovative applications such as tamper-evident labels and tapes, just to mention one growing application.)
The LAMBDA concept
Edale has put into its new Lambda over 50 years’ experience in the design, manufacture and development of narrow web printing and converting machines. The Lambda has taken not just the RFID element into account but the whole range of added value, intelligent narrow web applications, hence one machine for many applications. The combination guarantees low machine investment risk, high productivity and profitability with faster return on investment.
The initial investment can start with one base module and the modules for wet inlay RFID application. With just a few additional rollers, the same machine can be used for multi layer label application. At any later stage, a second, third or even fourth base module can be added together with a unlimited range of options such as:
- vacuum drum for dry inlays
- upgrade to multi-across production
- hot melt (UV or conventional)
- adhesive coating by flexo, gravure or screen process
- hologram and magnetic strip or placing
- any type of conventional printing units
- digital ink jet printing for personalisation
- sheet and/or zig-zag delivery options
- etc.
Summary
RFID converting has moved from a new technology to a mature status with pooled knowledge from the whole supply chain. It is not, however, an application for the faint hearted and as explained, in-depth knowledge is a must to avoid expensive and potentially deadly investment risks.
Choose an industry partner who can demonstrate and provide a wide range of solutions by explaining the pros and cons and not just a dedicated one-application supplier.
Drupa offers an excellent opportunity not just to test the water but to go beyond and compare the various RFID converting machine options available on the market.
RFID is just one part of a wide range of commercial security applications provided by Edale. The company has a long history of expertise and can offer not just RFID but many other bespoke printing and converting solutions. Design and configure your own machine is not just a slogan – it is reality.
The End - 1,158 Words
Added: 11-06-2008
