Discover how AI is transforming the automatic labeling process in production lines with a high variety of products and formats.
In an increasingly competitive and dynamic industrial environment, production lines must constantly adapt to a growing variety of products, formats and regulatory requirements. This diversity, especially present in sectors such as food, chemical and cosmetics, forces companies to rely on labeling solutions capable of delivering accuracy, speed and flexibility without compromising quality.
Artificial intelligence (AI) has emerged as a key tool to transform this process. Through technologies such as machine vision and machine learning, it is possible to automate complex tasks, adapt in real time to multiple product variables, and significantly improve operational efficiency.
This article discusses how to integrate AI into automatic labeling systems to solve some common challenges, increase productivity and ensure compliance with current regulations, especially on lines with high SKU turnover and diverse formats.
Challenges of labeling in multiformat production lines
Modern production lines, designed to meet diversified and customized demand, face several technical challenges in the labeling process:
Variability in formats and packaging
The need to label containers of different shapes (cylindrical, flat, conical), sizes and materials (plastic, glass, cardboard) requires adaptive labeling systems.
Frequent format changeover, without efficient automation, generates downtime and risks of error.
2. Manual adjustments and lack of flexibility
In many traditional, non-automated systems, adjusting the equipment for each product change involves manual intervention, which increases downtime and can lead to human failure.
In addition, these adjustments often require operators with technical expertise, which increases the dependence on the human factor.
3. Regulatory compliance and traceability
Regulated sectors (food, chemical, cosmetics) must comply with specific regulations regarding mandatory information on labels, such as batches, expiration dates, ingredients, chemical hazards, etc.
Any errors in labeling can lead to penalties, product recalls and loss of confidence.
4. Hidden costs due to errors and reprocessing
Incorrectly positioned, twisted or incorrectly labeled labels result in product rejection, reprocessing or even discarding, generating cost overruns that directly affect profitability.
Is your production line ready to adapt to multiple formats without compromising efficiency?
At MarCoPack we develop automatic multi-format labeling solutions that integrate advanced technologies to minimize errors, reduce changeover times and dynamically adapt to your production.
Contact us for a customized technical consultation.
AI applications in automatic labeling
Artificial intelligence brings a decisive advantage in automatic labeling by enabling continuous adaptation of the system to variations in product, environment and operational demand. These are the main areas where AI is already making a tangible difference:
Artificial vision for detection and positioning of containers
One of the great challenges of automatic labeling is to ensure correct label placement, especially when handling containers with slight variations in shape or alignment on the conveyor line.
Using high-resolution industrial cameras and machine vision algorithms, the system is able to identify:
- The exact position of the container.
- Its orientation with respect to the axis of application.
- Presence of defects on the surface of the container that could affect the adhesion of the label.
AI benefits: real-time optimization of label positioning, reducing errors and increasing operational efficiency, even in high-speed environments.
2. Machine learning for dynamic parameter optimization
Systems equipped with machine learning algorithms continuously analyze line operating data (speed, error rate, adhesion conditions, ambient temperature, etc.). From this information, they can:
- Automatically adjust parameters such as application pressure, labeling head speed or adhesive temperature.
- Adapt to progressive wear of components without the need for human intervention.
- Predict and prevent failures before they occur, thanks to predictive analytics.
Benefits of AI: reduced downtime, increased equipment life and continuous improvement without direct technical intervention.
3. Error detection and automated quality control
With the integration of sensors and AI systems, comprehensive quality control can be performed without interrupting the production flow. These technologies enable:
- Verify that the label has been placed in the correct area of the container.
- Confirm that the label content (text, barcodes, QR, dates) is correct, legible and as expected.
- Automatically reject mislabeled products before they reach the packaging stage.
Benefits of AI: increased traceability, reduction of defective products in the market, and compliance with regulatory standards.
4. Adaptability in multi-format production environments
AI makes it possible to manage multiple references and formats without the need to manually reconfigure the machine. This is especially relevant in companies with flexible production, where small batches, customization or frequent packaging changes are involved.
By automatically recognizing the container format, the system adjusts its behavior to suit:
- Product height and diameter.
- Type of label (wrap-around, front, top, etc.).
- Number and location of required labels.
Benefits of AI: increased versatility and ability to respond to market demands with agility.
Want to know how to optimize your production line?
At MarCoPack we integrate different technologies in our automatic labeling solutions, offering our customers a clear competitive advantage. Contact us, and find out how we can improve your labeling process.
Strategic and operational benefits of AI integration in automatic labeling
Implementing artificial intelligence not only transforms the operation of labeling equipment, but brings value at a strategic level. The following describes key benefits from an operational and business perspective:
a) Productive scalability without a proportional increase in resources
AI makes it possible to expand production capacity without the need to significantly increase human resources or make structural changes to the line. This is key to:
- Growing companies that want to scale without losing efficiency.
- Production for campaigns or seasonal products that require flexibility.
Advantage: orderly and profitable growth without compromising the quality of the process.
b) Data-driven decision making (data-driven manufacturing)
AI systems collect and process large volumes of data in real time. This information is converted into useful knowledge for:
- Improve production planning.
- Detect bottlenecks and opportunities for improvement.
- Anticipate incidents before they affect performance.
AdvantageOperational intelligence applied to continuous improvement.
c) Alignment with Industry 4.0 and access to subsidies
Intelligent automation positions the company within the framework of Industry 4.0, facilitating access to:
- Aid programs for industrial digitalization (such as the Digital Kit or the Cervera/CDTI programs).
- Innovation and sustainability certifications.
- Alliances with customers or partners that require digital traceability.
AdvantageImproved corporate image, access to public financing and preference in industrial tenders.
d) Reduction of dependence on the skilled operator
One of the frequent problems in production is the need for technical personnel for adjustments or troubleshooting. AI makes it possible:
- Standardize repetitive operational decisions.
- Minimize the impact of turnover or absence of experienced personnel.
- Train new operators with less learning curve thanks to guided systems.
Advantage: greater operational stability and plant autonomy.
e) Competitive differentiation
In industries where margins are tight and product life cycles are short, speed to market is essential. AI applied to labeling makes it possible:
- Customize products more easily (promotions, languages, formats).
- Reduce time-to-market for design changes or new product launches.
- Demonstrate technological capability in the face of customer audits or inspections.
AdvantagePositioning as an advanced and flexible supplier in the value chain.
Integrate value, not just technology.
Artificial intelligence is not just a technical improvement: it is a lever for operational transformation. At MarCoPack we help you identify real opportunities for intelligent automation that translate into economic and strategic benefits for your plant.
Request a productivity improvement diagnosis with process automation.
MarCoPack automatic labeling machines
Flexibility and customization are key aspects of modern production line labeling. MarCoPack offers a complete range of solutions that combine accuracy, speed and adaptability, while integrating advanced intelligent automation options and integrated solutions to maximize throughput.
The following are some of the most representative solutions for multi-format industrial environments:
1. MCP 350T: High precision and high speed
The MCP 350T is designed for high-demanding environments where label application accuracy is critical. Ideal for industries such as cosmetics and pharmaceuticals, where labeling tolerances are minimal.
Outstanding features:
- High accuracy even at speeds up to 150 containers/minute.
- Possibility of labeling on top, front, back or envelope.
- Compatible with machine vision systems for quality control and data verification.
Typical application: cosmetic bottles, pharmaceutical bottles, high-end packaging.
2. MCP 700T: Robust solution for industrial lines
The MCP 700T is designed for high-demand industrial work environments, where robustness and adaptability to different formats are required.
Outstanding features:
- Supports heavy workloads in continuous shifts.
- Configurable for top, side and wrap-around labeling.
- User-friendly interface for agile format changes.
Typical application: Industrial chemicals, drums, boxes and large volume containers.
3. MCP 600T: Multi-format Versatility
The MCP 600T is designed to adapt quickly to different types of containers and formats, making it ideal for flexible production and frequent changeovers.
Outstanding features:
- Possibility of applying labels simultaneously at the top and bottom.
- Ideal for lines working with flat containers, trays or jars.
- Compatible with thermal printheads or in-line printers.
Typical application: food trays, packaging for cosmetics or drugstore products.
4. MCP 400T: Labeling with tamper-evident seal
This solution is optimized for products that require labeling with a security function, such as seals or tamper-evident labels.
Outstanding features:
- Precise application of seals on caps or closures.
- Possibility of adding coding (batch, date, etc.).
- Compact design and adaptable to existing lines.
Typical application: Canning jars, sealed cosmetic products, chemical bottles.
5. SET 200: Efficient solution for medium production
Designed for cylindrical containers, the SET 200 offers a balance between speed, precision and operational simplicity, making it an ideal choice for medium production runs.
Outstanding features:
- Application of one or two labels on cylindrical containers.
- Agile and tool-less format changeover.
- Robust construction and easy maintenance.
Typical application: Oil bottles, shampoo bottles, detergent containers.
Solutions for today, scalable for tomorrow.
Each production line has specific needs. At MarCoPack we offer labeling machinery that grows with your business, adaptable to the integration of artificial intelligence, machine vision and industrial connectivity.
Ask our technical team which model best suits your production and investment.
Application examples
The integration of AI in automatic labeling is already being used in real industrial environments in highly demanding industries. Let’s look at some concrete application examples in the food, cosmetics and chemical industries:
a) Food industry: agility and regulatory compliance
In production lines of fresh products, canned or prepared foods, where labeling must contain mandatory information such as allergens, batches, expiration dates and traceability, AI allows:
- Verify in real time that the label corresponds to the correct product.
- Automatically adapt to format changes (trays, jars, cans).
- Automatically reject mislabeled units without interrupting the line.
b) Cosmetics industry: multiformat production and aesthetic precision
The cosmetics sector works with a high turnover of references, variability of formats and aesthetic requirements in labeling. AI has made it possible:
- Detect imperfections in label placement on small and non-standard shaped containers.
- Adapt the application system automatically to the type of cap or closure.
- Print variable information (e.g., pitch or formula) with automatic visual validation.
c) Chemical industry: safety and traceability
In chemical labeling, it is crucial to comply with regulations such as CLP or REACH. AI integration offers:
- Detection of errors in hazard symbols or pictograms.
- OCR/OCV verification of printed content.
- Automatic recording of labeling data for audits.
Implementation considerations
The adoption of smart labeling systems should be approached as a strategic project that combines technology, training and technical support. These are the keys to successful integration:
a) Technical evaluation of the existing line: It is necessary to audit the current production line to define compatibility with intelligent systems. It should be analyzed:
- Type and speed of production.
- Product variability.
- Control and automation systems already installed.
b) Establishment of clear objectives : Before implementing AI solutions, concrete objectives must be defined in order to correctly size the investment and measure its return:
- Reduce errors?
- Minimize changeover times?
- Increase productive capacity?
- Comply with traceability regulations?
c) Training and technology transfer: AI does not replace the operator, but assists him. Therefore, it is vital to train technical personnel so that they can:
- Interpret the data generated by the system.
- Make minor adjustments if necessary.
- Take advantage of the self-learning functions of the system.
d) Choice of a specialized supplier: The success of the integration depends to a large extent on the supplier. MarCoPack offers:
- Previous technical consultancy.
- Custom engineering.
- After-sales assistance and technological upgrades.
Artificial intelligence applied to automatic labeling is not a future trend, but an innovative solution for production lines seeking efficiency, flexibility and regulatory compliance. Whether in high-turnover food environments, cosmetic lines where aesthetic precision is paramount, or heavily regulated chemical facilities, AI brings control, adaptability and traceability.
In this context, having a technology partner like MarCoPack – with expertise in multi-format solutions, integration of third-party solutions, and advanced automation – represents a strategic advantage to meet the current and future challenges of the industry.
Do you want to transform your labeling line into a smart and scalable solution?
Contact MarCoPack and find out how our solutions can improve your operational efficiency and adapt to the demands of your industry.
Request personalized advice here.
Jose Martínez
Director Oficina Técnica MARCOPACK
