By integrating a high-speed rewinder with a PIJ (piezoelectric inkjet) printing system, we have developed the “Smart Inkjet Printing & Rewinding All-in-One Machine.” This system is designed for high-volume industrial environments, this sophisticated platform seamlessly integrates rewinding, alignment correction, plasma surface treatment, high-resolution inkjet printing, UV curing, and automated label collection into a single, highly stable workflow.
Core Technical
Precision Engineering & Control
At the core of the system is a robust rewinding unit governed by a high-performance PLC and an intuitive 7-inch color HMI. This advanced control architecture delivers precise tension management and synchronized speed control. A critical anti-loosening feature engages during stops to maintain web integrity and prevent material waste. The system supports a label width of 600mm and achieves a maximum mechanical speed of 180 meters per minute.
Precision Performance
With a repeat positioning accuracy of ±0.05mm, it ensures every pallet is perfectly aligned, improving stability during transport.
Super Accuracy & Adhesion
To maintain flawless quality at high speed, the system utilizes an Automatic Alignment Correction module. Using high-precision photoelectric sensors, it monitors label positioning with an accuracy of ±1mm. If any deviation is detected, the system automatically recalibrates the web in real-time. To ensure industrial-grade durability, an integrated plasma treatment machine prepares the substrate, ensuring perfect ink adhesion even on challenging or non-porous materials.
High-Resolution, High-speed Printing
The system is powered by our IPS-6501 PIJ Printer, delivering ultra-high-resolution marking at incredible speeds. While the rewinder operates at 180 m/min, the IPS-6501 is capable of reaching up to 380 meters per minute depending on the substrate. Immediately following the print stage, a high-efficiency UV curing system dries the ink in under around 0.2 seconds, allowing for instant, smudge-free label collection.
High-Resolution, High-speed Printing
The system is powered by our IPS-6501 PIJ Printer, delivering ultra-high-resolution marking at incredible speeds. While the rewinder operates at 180 m/min, the IPS-6501 is capable of reaching up to 380 meters per minute depending on the substrate. Immediately following the print stage, a high-efficiency UV curing system dries the ink in under around 0.2 seconds, allowing for instant, smudge-free label collection.
Versatile & Future-Proof
Engineered for operational flexibility, the system allows for rapid label changeovers and effortless printhead adjustments to satisfy diverse application requirements. This integrated solution is the ideal choice for manufacturers who demand rapid throughput and superior traceability without sacrificing precision or performance in the most demanding production environments.
Equipment Configuration:
| Component | Technical Description |
| Rewinder | Managed by a high-performance PLC with a 7-inch color touch-screen HMI; features constant tension control, stable speed adjustment, and anti-loosening functionality during stops. |
| Web Guiding System | High-precision frame-type edge position control; utilizes photoelectric sensors for a correction accuracy of ±1mm. |
| Plasma Treatment | Prepares the substrate surface to provide the ideal physical and chemical foundation for ink adhesion. |
| PIJ Coding System | Equiped industrial-grade piezoelectric heads supporting 600 DPI vertical resolution and adjustable horizontal resolution from 120–2400 DPI. |
| Curing System | Integrated UV curing lamps designed for “instant-dry” performance to match high-speed production. |
| Tension Control | Both unwinding and rewinding units utilize constant tension control to ensure smooth material handling. |
Integrated System Architecture
Hardware Integration
Mechanical structure: Modular Design, the printing system is strategically installed between the traction and rewinding sections of the machine.
Precise Synchronization: High-resolution encoders and color mark sensors detect material position to trigger precise printing.
Process Sequence: Plasma treatment occurs first to prepare the surface, followed immediately by inkjet printing and UV curing.
Software & Control
Centralized Logic: PLC-based control with a user-friendly touchscreen interface.
Advanced Printing Software: Professional variable data editing software that supports custom development for specialized applications.
Equipped with USB and TCP/IP network interfaces for seamless data transmission.
Typical Application Scenarios
Post-Print Label Coding: Adding variable QR codes, anti-counterfeiting codes, and dates during the rewinding process. Supports GS1, 1D, and 2D barcodes.
Flexible Packaging Data: Printing batch numbers and traceability codes on film materials where UV ink dries instantly to avoid affecting downstream processes.
Wide-Format Roll Printing: For large-width materials, the system utilizes multi-head stitching and high-precision guiding for extensive or multi-location coding.
Solution Advantages
Multi-Purpose Efficiency: A single platform handles rewinding, guiding, plasma treatment, printing, and curing, significantly reducing equipment investment.
High-Precision Results: The ±1mm alignment correction combined with high-quality inkjet output ensures barcode quality reaches Grade A or above.
Production Boost: Reduces material handling and reloading, lowering labor costs while maximizing throughput.
Full Traceability: Supports large variable databases and real-time dynamic data printing to satisfy “One Item, One Code” requirements.