Before labels and labeling products are produced in series, there is often a multi-stage development process where the label manufacturer works closely with the customer. In this process, robos-labels produces true-to-original sample labels according to the customer requirements. These labels are tested in detail according to a wide range of criteria and standards. The measurement results are bindingly documented in the corresponding templates. The QM departments on the manufacturer and customer side issue the production release when all requirements are finally fulfilled.
By testing and measuring a wide range of parameters, robos-labels ensures that all legal requirements and the customer’s requirements for the label are met. This allows the customers to transfer most or all of their testing requirements to robos-labels and to be on the safe side themselves. The highest quality standards for labeling are in the automotive industry, where the regulations of the German Association of the Automotive Industry (VDA) are applied.
You can find exciting practical information in the following interview with Christos Emmanuil, Head of Quality Department at robos-labels:
Mr. Emmanuil, what is meant by the sampling of labels?
The aim of sampling is to produce a sample ready for serial production. In a first step, the customer may receive only a functional sample of limited suitability, the so-called A-sample. This can be used to give the customer a rough idea of what their products will look like. For samples that are ready for serial production, documentation including a wide range of measurements and laboratory tests is required. Materials are documented by data sheets from the manufacturer or by tests performed by an external laboratory. The tests include, for example, migration tests on labels for the pharmaceutical industry or tests for UL approval as well as tests for resistance in seawater. Different products have different requirements that we have to verify. The customer must be sure that the lasting quality and product properties in the future will correspond to the production-ready sample of today.
How many sampling levels are there?
There are 5 sampling levels according to which sampling can be performed. The sampling method is agreed with the customer. For each phase the corresponding samples can also be produced (development, prototype, pre-series or series). Depending on the phase, these are also called A, B or C samples.
The first sample does not have to be final, but may only show certain product characteristics such as the print image or the material. The customer’s product is also often still in a development phase and the dimensions may still be changed and adapted. During further sampling, the parameters modified by the customer are recorded and implemented and the label is further developed. The production-ready sample is the C sample, which can also be validated.
Which aspects are covered by sampling?
Dimensions, materials, physical and chemical product properties, resistance and appearance will be documented. For example, it will also be verified which production steps are carried out by an upstream supplier. We are responsible for our suppliers. The packaging of our products is documented as well, such as the thickness and weight of the film, information on the pallets, etc. in the form of a packaging data sheet. For export to Italy for a customer we had to provide precise information on packaging film, its weight and recyclability. In another past production run, the size and position of over a hundred Chinese characters were individually measured and documented for a label in order to ensure later machine readability.
What are the advantages of sampling before actual production?
Sampling ensures that the product meets customer requirements. A positive exchange between us and the customer also ensures that there are no unanswered questions on either side at the end of the sampling process. Thus sampling generally serves to assure both sides that serial production will be feasible and reproducible as well. The customer can also make a complaint on this basis if necessary. Thus sampling serves as a guarantee of the product quality supplied.
Which rules and regulations is sampling closely related to?
Although we are ISO 9001 and ISO 14001 certified, we also meet the required standards of the automotive industry for sampling. The German Association of the Automotive Industry (VDA) defines the framework conditions for production and process release (PPR). PPR sampling is a process that ensures that the technical requirements for the product and the manufacturing process have been understood by the supplier and that the label manufacturer is able to deliver the labeling product in the required quality. The Automotive Industry Action Group (AIAG) is the American equivalent of VDA and has defined a corresponding process (PPAP).
What surprising findings have emerged from sampling in the past?
The fact that even with a supposedly simple label you can find a variety of ways to influence errors. No matter how complex or seemingly simple a label appears – nothing can be taken for granted. Sampling uses a systematic approach to detect potential errors that can occur before, during and after the production phase.
At what point does sampling come into play?
The point in time and the person triggering the process on the customer side vary. The impulse often comes from strategic purchasing or quality assurance. In an early product development phase also clearly from the development department. Thus we always offer sample quantities in addition to the subsequent series quantities in these cases. We produce these sample quantities in advance for many customers. In particular, in the automotive industry our accompanying and subsequent measurements are cross-checked and adjusted by the customer. In addition, an annual requalification must be made to prove that the processes are still stable.
For which labeling products are the samples particularly valuable?
This is particularly the case with functional labels, such as e.g. control foils, where LED lights must shine through a precisely defined small area.
How much lead time must be calculated for a sampling?
If a so-called “cover sheet sampling” with few details is required, a sampling takes approx. 30 minutes.
A sampling with various or even critical features takes several hours, but can also take several days if not all measurements can be fulfilled with your own on-board resources.
In these cases, we work together with an accredited laboratory in Stuttgart. Basically, it can be said that the more characteristic measurements are required, the greater the testing and documentation effort.
What are the costs of a sampling?
A sampling can cost between 90€ and 1500€ depending on the effort involved. In complex individual cases, however, even more.
For this reason, we try to work with the customer in advance to assess what is really needed in order to avoid unnecessary expenses on both sides.
What should customers know about sampling?
Many customers have standard requirements, regardless of which product is procured. Here we often encounter requirements from the metal and mechanical engineering industries, some of which are not transferable to labeling products.
In such cases, we have had the best experiences when we together with our customers anticipated what is required and what is feasible in terms of labels.
Thank you for the interview.
The interview was conducted by Christine Hartmann (Corporate Communications)
