Case Study

Solving a Label Scuff Problem through Design of Experiments (DOE)

A global beverage group asked G3 Label to optimize label coating performance for one of their most popular wine brands. They found that ink had the potential to scuff off the embossed high points of their label when tested during receiving inspection. In order to find the best solution G3 used a process modeling approach called Design of Experiments or DOE.

Through our experiments we identified which press settings are most critical for creating excellent scuff resistance. Our resulting process model allowed us to quantifiably correlate UV intensity and label emboss height to ink scuff resistance. It showed that coating options were important but our original least expensive coating could meet our customer's criteria with optimized press settings. The process model told us that line speed had little effect on the label scuff resistance allowing us to run the jobs more efficiently. Ultimately were able to balance customer expectations and cost and we quickly applied the knowledge gained to other similar equipment.

A DOE approach allows you to explore more possibilities and correct false assumptions with less time and resources than adjusting one process setting at a time. First we identify the intended outcome, and find a way to rate or quantify it. Then we identify all of the variables in the process that might affect that outcome such as machine settings, tooling and raw material characteristics. We design an experiment and execute it on-line then statistically model the results. G3 has modeled dozens of processes with DOE and offers process modeling as a consulting service. Contact Us!