Changeover control
Bottle Labelling Machine Changeover Checklist.
Create a repeatable setup for every bottle and label format.
Need a bottle labelling machine specified quickly? Send bottle dimensions, label size and output target.
Request specification adviceCall 01494 623015Treat changeover as a controlled return to a known setup.
A reliable changeover is more than moving guides until the bottle passes. The operator must confirm the correct container, label, artwork, web direction, sensor method, application position and machine settings, then approve a first-off sample before normal production resumes.
| Step | Action | Evidence |
|---|---|---|
| Prepare safely | Stop and isolate the machine as required by the manufacturer's instructions and site procedure before entering guarded or hazardous areas. | Authorised operator and the correct changeover procedure. |
| Clear the previous format | Remove containers, labels, backing waste and loose parts; clean the web path and sensing area using approved methods. | No mixed labels, containers or obsolete settings remain. |
| Set product handling | Adjust guides, separation, top hold, wrap belt or product support for the new container. | The product travels without rocking, excessive pressure or uncontrolled rotation. |
| Load the label roll | Confirm identity, unwind direction, web path, tension, edge guidance and waste take-up. | The label presents in the correct artwork orientation and tracks consistently. |
| Set sensing and position | Select or adjust the label sensor and product sensor, then set label height, start position and front/rear relationship. | Stable detection and a marked or approved placement reference. |
| Approve first-off | Run a controlled sample, inspect label identity, position, adhesion, code and barcode where applicable. | Signed or recorded first-off approval before the batch continues. |
Record what actually saves time
Useful format records identify the container and label precisely, show the web path, note guide or head reference positions, list recipes or settings and include a photograph of the approved pack. A single generic setting is rarely sufficient when bottle height, diameter, taper, label length or surface material changes.
Common changeover errors
- Correct label design wound in the wrong direction.
- Guide pressure that distorts a lightweight bottle.
- Sensor sensitivity copied from an opaque label to a clear construction.
- Label start position changed without checking wrap overlap or front/rear relationship.
- Coder or inspection recipe left on the previous product.
- First-off approved on an empty bottle although production uses a filled and capped pack.
Escalate rather than compensate
Repeated manual corrections, unstable sensing, web wander or a product that cannot pass without excessive guide pressure should be investigated. Do not bypass guards, interlocks or safety functions to shorten a changeover. Maintenance and electrical work should remain within the competence and authorisation defined by the site and manufacturer.
Use the label-roll worksheet, clear-label sensing guide and troubleshooting guide to build format-specific checks.
Define the format family before machine specification.
Send the smallest, largest and most difficult bottle and label combinations, plus the expected changeover frequency.