The AP360/AP362/AP380 stops during label application or you have to press the foot switch twice to complete the application.

The AP360/AP362/AP380 stops during label application or you have to press the foot switch twice to complete the application.

The applicator stops because the sensor that detects gaps between labels was tripped.  The sensor is a physical flag sensor which is a piece of light metal that keeps in contact with the front of the label stock as it moves.  When you press the footswitch it starts the motor and keeps running it until the sensor detects the gap between labels.  That gap makes the piece of metal move up slightly which then stops the motor.  There are several things that can trick that sensor into thinking it has hit a gap (which will stop the application process)

1. Creases or folds in the label stock.  Only smooth continuous labels from rolls should be used in the applicator. 

2. A container that has ridges or bumps that cause it not to roll smoothly.  Full glass bottles are usually very smooth unless the glass has a pronounced seam where two parts were molded together.


3. Any bubbles in the label stock caused by a slipping roller.  For example, if the liner drive roller at the top is slipping as it is trying to pull the label stock through it will cause a bubble in the stock.  This is because the roller turning the container and the roller pulling the liner are effectively moving at different speeds. This is caused by the label bouncing during the application process.  If the label bounces up it causes the sensor to move back to its home position at the peel edge.  If the sensor moves, the AP362 thinks the label has been applied and stops.

Try the following additional solutions:

4. Push down lightly on the container pressure arm during application.  You can also adjust the tension of this arm.  To set it properly, push the container pressure arm slightly below the top of your container.  The arm is spring-loaded and should allow you to slip the container into position and maintain pressure.  This video explains the process at 3:10. 



5. Move the label sensor closer to either side edge of the label or toward the center if it is already at the edge.


6. Move the container idler roller closer to the container drive roller.  It should be as close as possible while still providing enough support to hold the container.

7. Place the container on the applicator while the drive roller is moving.  Watch the container for excessive up and down movement.  If the container shape is not a perfect cylinder it will cause the label to bounce.  Remove the container from the applicator.  Press the footswitch.  Be ready to catch the label as it comes off the peel edge.  If it comes completely off, you know the container is causing the problem.  

8. Very light plastic containers can also cause bouncing.  Try filling the container before applying the label.

9. Wrap labels around the liner idler roller.  If your model does not support clamp force adjustment, to increase pressure, You can also try wrapping a few labels around the liner idler roller (silver roller). Start with one or two layers of labels and add more if it doesn't work. I recommend using a synthetic label (Poly, BOPP, Vinyl) that will not break apart when/if you want to remove the label from the roller in the future.

10. Increase liner clamping force (newer model AP380 only). Use the adjustment screws on either side to increase clamping force.  This is especially useful if you have a very thin liner.  Typically, clear liners are thinner and are more difficult to feed through the machine with out slipping.  See this article.

11. Adjust the Liner Drive Speed. (AP380 Only with firmware greater than 25.)
If the AP380 stops in the middle of the application, it may be caused by the liner drive roller motor and the container drive roller not being synced at the same speed.  This can cause a bubble to form between the liner drive roller and the peel edge.  It may take several labels for this problem to appear..  To adjust the Liner Drive Speed press and hold the “+” and “-“ for 3 seconds until the display shows “A-x”   x= the current speed setting.  Default = 5. Use the + or – buttons to increase or decrease the speed.  After making the adjustment, apply several labels to determine if the new speed setting resolves the speed difference. 

12. (Advanced Option!)  You may also adjust the label sensor trigger point if it has come out of calibration.  The sensor flag trigger point may be too close to the container drive roller.  If that is the case, the slightest bump/bubble in the label will cause the liner drive roller to stop, therefore stopping the label from applying.  It should be stopping the liner drive roller between .042 and .058 inches from the peel edge.  You can gauge the trigger point by removing labels and containers from the applicator and then depressing the flag so that it is touching the container drive roller.  Press the foot switch.  Now slowly let the flag fall back toward the peel edge.  It should stop the liner drive roller between .042 and .058 inches from the peel edge.  You can make a gauge by measuring the thickness of several sheets of paper or Post-It notes.  .058” is approximately 15 Post-It notes.  (13 Post-It notes was .042”.)  If it is out of position you can BEND the sensor flag into position.  There is a pivot point on the sensor flag that can be bent by hand. 



Article ID: 54343