Excessively high line speeds
Labelling machines struggled to maintain synchronisation and application precision.
Analytical Case Study
High-definition direct marking on ceramic boxes.
How Colceramica (Corona Group) replaced automatic labelling machines with HD inkjet printing systems directly on the cardboard, increasing reliability and production efficiency.
The evolution of traceability requirements and line speed
In the ceramics sector, information printed on packaging boxes is becoming increasingly strategic for logistics management and product traceability.
Colceramica (Corona Group) needed to introduce high-definition QR code printing directly on cardboard boxes, ensuring consistent quality and perfect readability.
At the same time, the continuous increase in production line speed was making the application of traditional adhesive labels increasingly critical. Boxes were moving at high speeds and the labelling system showed clear operational limitations: difficulty with precise application, misaligned labels, code readability issues, and increased line stoppages.
The increase in line speed and the introduction of QR codes made traditional labelling machines insufficient.
Printing high-definition QR codes on high-speed lines
The problem was not only about print quality, but the ability of the system to maintain precision and reliability at the new production speeds.
Inconsistent QR code quality
Even minor application defects compromised code readability.
Mechanical system limitations
Rollers, drives and applicators were subject to continuous wear and adjustment.
Production stoppages and maintenance
Label reel replacements and mechanical adjustments slowed down production.
Why direct printing represented the true paradigm shift
During the technical analysis, a fundamental point emerged: the limitation was no longer print quality, but the very presence of the physical label within increasingly fast lines.
High-definition inkjet printing directly on cardboard completely eliminates the mechanical step of label application, making the system more stable, faster and compatible with the new production requirements.
| Parameter | Previous solution | New solution |
|---|---|---|
| QR code management | Limited | Optimal |
| Print quality | Variable | High and consistent |
| Line speed | Critical | High |
| Mechanical components | Many | Reduced |
| Production stoppages | Frequent | Reduced |
| Data flexibility | Medium | Total |
HD inkjet printing system directly on cardboard
The proposed solution involves the installation of high-definition inkjet printers integrated directly on the packaging line.
Objective: print all necessary information directly on the box, including highly readable QR codes, completely eliminating adhesive labels.
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High-definition printing
QR codes, texts, logos and variable data perfectly readable.
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Direct marking
Complete elimination of the physical label.
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Real-time data
Automatic update of codes and production information.
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Reliability at high speeds
Consistent precision and quality even on very fast lines.
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Reduced maintenance
Fewer mechanical components compared to labelling systems.
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Reduced operating costs
Elimination of consumables related to adhesive labels.
From mechanical management to digital printing
The client faced two main requirements: improving the quality and readability of the new QR codes, and eliminating the operational limitations of traditional labelling machines.
The approach adopted was to completely simplify the marking process, eliminating the physical step of label application.
Through in-line print testing, an HD inkjet system was implemented capable of guaranteeing consistent quality, perfect QR code readability, high reliability at high speeds, production continuity and reduced line stoppages.
In the Field
Photo gallery of the project
Higher speed, higher quality and greater production continuity
Before
Labels w/o QR code
Previous system
After
100% HD QR code
Current system
After installing the HD inkjet system on a first pilot line, the client recorded immediate results in print quality, QR code readability and operational reliability, subsequently extending the solution to 9 lines in total.
| Metric | Result | Impact |
|---|---|---|
| QR code readability | +100% | HD direct marking on cardboard |
| Adhesive labels | 0 | Completely eliminated |
| Updated lines | +9 | Progressive extension after pilot |
| Line stoppages | Reduced | Fewer mechanical adjustments, no reels |
| Maintenance | Reduced | Mechanical components eliminated |
What this case demonstrates
The Colceramica case demonstrates that sometimes the best solution is not to optimise one component of the process, but to eliminate it: removing the physical label solves the mechanical limitations at their root and frees the line from the constraints of the previous system.
01
Eliminate rather than optimise
The most effective solution is not always to improve a process component, sometimes the real breakthrough is to eliminate it entirely.
02
Quality at the source
Printing directly on cardboard removes the variables of label application, guaranteeing consistent quality at any line speed.
03
Simplicity generates reliability
Fewer mechanical components means fewer failure points, less maintenance and greater production continuity.
Next step
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