Training Module
Labeller Operator
Training Module
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Module 1 – Introduction &
Objective
Training Module
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Introduction –
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A labeler operator in a bottling plant is responsible for ensuring
that the labeling process of bottles or containers is done accurately, efficiently, and
in compliance with quality standards. The operator manages the labeling
machinery, ensures the correct application of labels, and plays a key role in
maintaining product branding, traceability, and regulatory compliance.
Breakdown of the key duties:
• Setup and calibration.
Labeller
• Inspect label placement. Operator
• Verify label information.
• Manage label supply.
• Track labeling material consumption
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Module 2 – Machine Setup and Operation
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Machine Setup and Operation – Machine Setup and Operation
refers to the process of setting up and operating machinery for
production runs. It involves technical know-how, workflow
management, resource allocation, and time optimization to
minimize downtime and transition seamlessly between production
cycles.MARKET TECHNICAL FINANCIAL ECONOMIC
ANALYSIS ANALYSIS ANALYSIS ANALYSIS
Machine Setup and Operations are used in the following phases:
Lorem ipsum dolor Lorem ipsum dolor
• Startup Operation sit amet, sit amet,
consectetur consectetur
• Operating Operation
adipiscing elit, sed adipiscing elit, sed
• Changeover Operation do eiusmod tempor do eiusmod tempor
incididunt ut labore incididunt ut labore
• Shutdown Operation et dolore magna et dolore magna
Labelling
aliqua. aliqua.
Machine
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Start-up Operations - Starting up operations in a bottling plant for a Labeler
involves certain process to ensure that the production process is efficient, safe,
and meets quality standards.
Star-up Operations
1. Ensure General checkpoints for line startup as per laid down procedure.
2. Ensure all guards are in place & interlocks are working
3. Ensure all the changed parts are properly mounted and removal of all Blower Acostic
foreign objects Enclosure
4. Ensure printer is in good working condition and properly clean
5. Check and maintain FRL air pressure in the machine
6. Check and maintain the oil level and oil lubrication point of the machine.
7. Check the condition of label sensor, pressure roller and dispensing edge
for a good quality labelling.
8. Ensure label quality as per specifications.
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Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Ensures all the emergency switches are accessible.
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Operating Operations - A Labeler Operator in a bottling plant plays a key role in ensuring that the labeling process is conducted
efficiently, accurately, and in compliance with regulatory standards.
Operating Operations
1. Follow a standardized approach for the proper operation of Labeller Machine
2. Check all the label mandatories before mounting the label roll on the machine.
3. Frequently check coding & ensure that the adjustment of height & width to match
the legal requirement
4. Use computerized systems to monitor and control bottling processes.
5. Ensure minimal wastage and removal of the butter paper from dispenser before
the error arise.
6. Adjust delay setting of dispenser unit.
7. Set the delay value according to the shifted label
8. Check and adjust the angle & height of air knife as per the SKU in production.
9. Ensure Inspection of the back side of labels for Batch no & Date, Print cut and
Print Smudge.
10. Ensure that the nozzle alignment & washer setting is checked thoroughly.
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Be alert for any malfunctions in the inspection system.
Be familiar with emergency procedures in the event of a machine malfunction, fire, or other workplace emergencies.
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Changeover Operations - It refer to the process of switching production lines from one type of product to another, a fitter plays a
crucial role in ensuring a smooth and efficient changeover by reconfiguring electrical systems, ensuring equipment compatibility etc.
Steps for Changeover
1. Ensure integrity of the release plates and brush bristles for proper positioning
and alignment.
2. Ensure air knife mounting angle should be at 45 degree from the horizontal.
3. Ensure removal of old bottle’s change parts and replace with the required sized
bottles.
4. Adjust the feed worm mounting frame gap for the required size of bottles.
5. Trouble shoot equipment issues to meet productivity standards
6. Adapt to changes in production requirements or new labelling technologies.
7. Ensure all pneumatic and mechanical joints & connections are in good
connection
8. Adjust the height of the Dispenser by rotating the Hand-wheel
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Perform any activity on the machine when power is off.
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Shutdown Operations –
upgrades, or safety checks.
A shutdown operation typically refers to temporarily halting production to perform maintenance, repairs,
Procedure for shutdown –
1. Properly sequence shut down inkjet/ laser printer inline. Do flushing if required.
2. Remove releasing papers from the dustbins.
3. Return the unused label to Store for DG reconciliation as per SOP.
4. Check machine guards like conveyor below the snake guide, the guard for dispenser
and rewinder motor and ensures doors are properly closed.
5. Ensure all electrical and pneumatical machines are isolated.
6. Complete the shutdown following the shutdown procedures., logs & notes down
the time, reason, and any issues encountered.
Switch Off Button
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Be familiar with emergency procedures in the event of a machine malfunction, fire, or other workplace emergencies.
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Module 4 – Maintenance & Troubleshooting
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Maintenance & Troubleshooting – Maintenance & Troubleshooting ensures safety, efficiency, and the smooth
functioning of all mechanical components, contributing significantly to the overall productivity and profitability of the plant.
Routine Maintenance
1. Tighten and clean Dressing rollers & Brushes
2. Ensure regular checking of the condition of label dispenser, power cables and fuse and
replace it if required
3. Ensure cleaning of the Slat chain conveyor of the machine.
4. Ensure lubrication of tools and equipment whenever required
5. Possess the required skills in diagnosing and resolving minor mechanical issues
6. Follow 5’s principles for the production area
7. Troubleshooting Common Issues
8. Possess the required skills in diagnosing and resolving minor mechanical issues
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Module 3 – Safety Protocols
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Safety Protocolsanalysis
– slide 5
Health and safety in a bottling plant are critical to ensuring the well-being of employees, maintaining
product quality, and complying with industry regulations. Bottling plants, like other manufacturing environments, pose
various risks, including mechanical, chemical, ergonomic, and environmental hazards.
key steps to maintain Safety Protocols
Possess the knowledge of emergency response plans, including evacuation
routes and first-aid basics.
Identify and mitigate potential hazards and follow safety protocols. Anti cut gloves
Safety shoes
. Ensure all the emergency switches are accessible and area free from tripping
hazards
Understand and follow safety procedures to prevent accidents and injuries and
procedures for reporting incidents
Possess the knowledge of emergency shut-off procedures. Ear plug Safety google
Ensure that all equipment’s are properly earthed and guarded.
Ensure use of PPEs as per PPE matrix
Be aware of safety protocols when operating machinery.
Head cap Mask
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Module 5 – Quality Control & Performance
Monitoring
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Quality Control slide
& Performance Monitoring – 5 Quality Control (QC) and Performance Monitoring are critical
components of any bottling plant operations, labeller operator ensures proper labelling according to the product.
Ensuring Product Quality
• Ensure that all labels meet regulatory and quality standards, addressing any
discrepancies promptly.
• Possess the required knowledge of visual and functional inspection methods for
quality assurance.
• Ensure accurate records of any problems encountered, maintenance performed,
and changes made to the machine settings
• Ensure labels are applied correctly in terms of position, alignment, and orientation
on bottles
• Ensure maximum label roll dia that can be run in the machine should not exceed 400.
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Module 6: Documentation and Reporting
Documentation & Soft Skills
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Documentation
Calculate the actual output v/s designated output
Read and interpret technical manuals for setup and operation.
Follow maintenance schedules and procedures outlined in manuals.
Soft Skills
Ensure the team follows safety protocols
Define PI for their respective workstation.
Train co-workers on operations.
Maintain an effective communication with supervisors, maintenance personnel,
and quality control teams to resolve issues and optimize production flow.
Operational Excellence
Be proficient in operating and maintaining Labelling machinery and equipment.
Conduct regular checks for correct placement and alignments
Perform calculations for production rates, label quantities and material usage
Document work and maintain a clean workspace.
Ensure manufacture and expiration dates are mentioned on every product
Perform regular CIPs to ensure clean working environment
Understand specifications for label size, type, and adhesive requirements.
Identify top PI’s for the Machine and record them in SIC chart.
Understand and update OWS board elements including 20 element SOP.
Refer to the reaction Plan in case PI are out of threshold and act as per reaction plan.
Update reaction plan on timely basis
Understand the CCP’S & OPRP’s and actions to be taken to maintain CCP & OPRP
requirements.
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Tools required for machine ( Operation , Maintenance & Quality )
Allen key set ( 1.5 to 10 mm ) T-shaped Allen key set ( 1.5 to 10 mm ) ) Straight Nose pliers ) Bend nose pliers Universal pliers Screw driver Cross / Ball pien hammer
Tester Adjustable spanner One end Open and ring Spanner set Oil can Grease gun Measuring tape Mallet hammer
Spirit level Micro Screwdriver Screw driver Tool
Digital Multimeter Hex Tubular Box Rachet Spanner Set 90 degree Angle
Tool kit kit 65 pieces
Spanner Set (8-19 (8-19 mm)
mm)
Thank You
