Rotary Braille: a quality touch

Applying Braille to packaging can be a challenging process. Packaging specialist BOBST has developed an award-winning rotary embossing system that provides quicker make-ready times, lower tooling costs and wider design options.

The BOBST ACCUBRAILLE system, now used by packaging manufacturers worldwide for applying Braille to pharmaceutical packaging, has become a Best of Year award winner for innovative technology. The unit, which can be fitted on to a wide range of Bobst folder-gluer lines, resolves many difficulties associated with the traditional means of Braille embossing using a die-cutter.

	ACCUBRAILLE’s rotary system, once set, requires little or no operator intervention and can process millions of blanks per tool before changing.

Brazil’s Embanews Awards, now in its 20th year, recognises the best in packaging manufacturing and innovative packaging technologies. In 2011, it awarded first place to the ACCUBRAILLE system in the machinery, equipment and systems category. Dirceu Fumach, CEO of BOBST Group Latinoamerica do Sul, said that ACCUBRAILLE has revolutionised the process of applying Braille embossing to cartons.

“With ACCUBRAILLE on a packaging manufacture line, make-ready is very quick compared with die-cut and embossed make-ready, and much quicker than the two make-readies needed if you carry out embossing as a separate run,” he says. “The system can be set in less than five minutes, a massive improvement on the time needed for traditional methods.”

Rotary’s upper hand
The problems faced when embossing Braille using a die-cutting press include difficulty in setting and maintaining good Braille dot definition, the die-cutter’s restriction on embossing that must be no closer than 5mm to a cut or crease line and the feed issues created in the folder-gluer by blanks that have had Braille embossed on them by a die-cutter.

The ACCUBRAILLE module is a highly ontrolled rotary embossing unit placed between the blank aligner of the foldergluer and its pre-breaker. The male die, which is made up of four lines of Marburg Medium Braille text and bespoke for each drug/dosage combination, rotates in perfect synchronisation with the arrival of the carton, while a universal female die provides the counter for the male.

Because the rotary process is low impact, tools last much longer than those used in die-cutter embossing and, because the lower ACCUBRAILLE tool is universal, only one male embossing tool is required per job instead of the one per station needed using a die-cutter. Together, these characteristics mean that tooling costs are significantly reduced by using an ACCUBRAILLE system and the quick and easy manufacturing of these tools means that packaging makers can reduce the lead time required to get a carton to market.

Maintaining Braille dot definition on a die-cutting press also requires careful setting and control of the machine pressure and the operator has to keep a continuous watch for wear of the embossing dies. The rotary system, once set, requires little or no operator intervention and can process millions of blanks per tool before changing. Additionally, because it is applied after the sheet has been die-cut, the Braille can be applied to the edges of the carton, increasing designer options.

The ACCUBRAILLE system offers a further advantage over die-cutter embossed Braille: blanks embossed on a die-cutter often misfeed at the in-feed section of a folder-gluer because Braille dots interlock. Blanks for rotary embossing are perfectly smooth and so do not misfeed in this way, thus improving productivity. Additionally, the ACCUBRAILLE unit has been designed to keep pace with the folder-gluer, even at 100,000 cartons per hour.

Spirit of excellence
Winning the Embanews award involved the ACCUBRAILLE system going through an in-depth examination and testing process by a committee of 70 representatives from professional organisations, with the objective of acknowledging companies that ‘excel in their activities’.

Continuing this spirit of excellence, BOBST will launch its in-line quality control device at the end of 2011. Called ACCUCHECK, the unit will turn the folder-gluer line into a highspeed packaging print checker and is the result of over 13,000 hours of R&D activity. These and other BOBST developments will help pharma packaging manufacturers meet the increasing pressure from brand owners to deliver zero-fault packaging.

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BOBST

For further information, visit: www.bobstgroup.com