Industrial Coding & Marking
DIKAI customer case studies: the challenge, the solution and the measurable result.
Background: 1. The confectionery company's fruit gummy workshop is a lighthouse workshop that frequently receives visitors. The workshop has several multi-lane packers that originally used Luge high-resolution inkjet printers, one TIJ per lane. Installation space is very limited, and the workshop's overall appearance and "concealed engineering" must be considered. 2. Besides this workshop, the company already runs several DIKAI lasers in other workshops in the same region. Pain points: 1. Inkjet consumables are expensive, and replacing cartridges in the tight space is inconvenient. 2. The customer wanted to print factory secret codes on the packaging, but inkjet marks rub off easily. 3. After-sales response was slow. Customer needs and solution: The customer has several multi-lane packers, each with 6 lanes of products that all need marking on the film. 1. The multi-lane line produces 6 products at once, so all 6 must be marked at the same time. 2. Marks must be printed in the designated position on the film, clear and rub-resistant, for anti-counterfeiting and anti-diversion. 3. During production, an alarm is required whenever marking is not running. 4. Lasers must be installed in a protected, collision-safe area. 5. The installation must not block maintenance of the packer. DIKAI coding solution: 1. Choose the DLU500F air-cooled UV laser, suitable for multi-lane lines. Marks are clear and permanent for anti-counterfeiting and anti-diversion. Its unique laser control and air cooling mean no consumables, no chiller and a compact body. 2. Two DLU500F lasers are installed on each line and controlled independently. 3. Laser signals are linked with the packer PLC and alarm signals, so the system alarms immediately if marking has not started. 4. The operation screen is installed inside the packer guard for collision safety. 5. A reduced custom rack holds 2 lasers and is ceiling-mounted to save space and ease maintenance. Project highlights: 1. The customer purchased multiple lasers: no consumables, lower cost and higher efficiency. Marks are permanent and cannot be erased, preventing counterfeiting and diversion. 2. Heat dissipation: the DLU500F is compact with no chiller, which suits heat dissipation in tight spaces. As a lighthouse factory with frequent tours, multiple chiller tanks would take up floor space and look untidy, and concentrating them would hurt heat dissipation. 3. Service: the customer highly recognizes DIKAI's pre-sales and after-sales service. When day or night shift staff encounter problems, DIKAI responds immediately and actively solves them.
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1. Requirements: 1. Application: static coding on five-ampoule boards. 2. Material: milky-white 3ml and 5ml PE ampoules. 3. Content: product name + date, batch and specification. 2. Infrared picosecond laser solution: A slotted stop conveyor was built and a drop feeder was installed on it. Products are loaded manually into the feeder, which places them into the conveyor slots. When the sensor detects a product, the conveyor stops instantly and sends the marking signal to the laser; after marking, the conveyor returns a completion signal and the next product cycle runs. 5. After-sales service: Shanghai DIKAI is committed to customer satisfaction. The whole machine carries a one-year warranty and lifetime service. DIKAI has 1 headquarters, 4 branches and 13 offices in China plus authorized dealers. 1. After installation, operators and maintenance staff receive necessary training and have their questions answered so they master machine maintenance and use quickly. 2. The supplier provides on-site service and visits users every year to check equipment status, answer questions and inspect working conditions. 3. The supplier's service hotline offers 24/7 support all year round. 4. Lifetime service: failures get a response within 1 hour and on-site repair within 2 hours to 2 days. If a fault cannot be fixed immediately, a spare machine is provided. 5. After the warranty period, repairs are charged only for necessary costs.
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Background: 1. The confectionery company's color bean workshop has several packers, each with two film rolls, GP2408T models. 2. The twin-pack lines in the color bean workshop used traditional ribbon coders. 3. To meet market demand, the customer replaced the ribbon printers on the twin-pack lines, adding time codes for date and batch traceability, improving coding efficiency and quality and reducing manual errors. This plan provides a suitable coding solution based on the production process, product characteristics and site conditions. Pain points: 1. The customer wanted real-time time codes for traceability, which traditional ribbon coders cannot print. 2. The installation space is tight; the coder must not protrude beyond the packer. 3. Ribbon marks look poor and rub off easily, which does not help the product image. 4. Traditional ribbon coders are not intelligent: fixed type cannot print real-time time codes for anti-counterfeiting traceability. 5. Changing content means manually replacing type, increasing downtime, reducing efficiency and causing errors. Customer needs and solution: 1. The workshop has several packers, each with two independently running film rolls. 2. Continuous operation with intelligent control is required. 3. Installation space is tight. 4. The coder must be installed inside the packer without protruding. 5. The coder must link with the packer and communicate or stop when a fault occurs. 6. After-sales service must respond quickly. DIKAI coding solution: 1. Choose the DLU520e UV laser: clean and dust-free, suitable for twin-pack lines. Marks are clear and permanent for anti-counterfeiting and anti-diversion. 2. Each packer gets 2 DLU520e lasers that run independently without interference. 3. Custom laser frames are designed for the twin lines. 4. A 70mm x 70mm field lens is compact with a short focal length and simple installation. The chiller and controller can be installed separately to meet the site requirements. 5. The laser chiller is wall-mounted with about 6m of hose to keep the workshop neat. 6. Marking positions are confirmed before screen installation to avoid affecting daily operation and observation. Project highlights: 1. DLU520e UV lasers are installed on the multi-lane packers: marks are permanent, no manual content changes, intelligent production cuts cost and raises efficiency. 2. The customer strictly requires the laser not to protrude beyond the packer. The DLU520e is compact and fits the original ribbon coder space; the small chillers are hung together for management.
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Project background: A veterinary drug manufacturer and listed company whose main business is veterinary drug preparations has two production bases. One plant started an equipment upgrade project in 2025 to further improve line automation and product quality standards. For premade pouch packaging, the company already uses DIKAI's customized pagination machine with the DLU500X laser coding system, which runs stably with good results. Roll-film packaging is spread across three workshops with several Dewo vertical packers that currently use Markem X40 coders to print production date, expiry date and batch number. To improve coding efficiency and mark quality, sharpen the product image and reduce coding defects, the company launched the roll-film coding upgrade project at the end of 2025. Based on the production process, product characteristics, on-site space and customer needs, this plan provides a systematic solution combining coding and inspection to keep the equipment running stably and fully meet customer needs. Customer pain points: 1. Complex working environment: the products are powders, and the site has heavy dust and corrosive sugar. The existing equipment is not well adapted and long-term stability is hard to guarantee. 2. Mark quality and product image: the X40 marks have weak adhesion and are easily erased during production flow, causing packaging appearance defects and failing the consistency and aesthetics the customer expects. 3. Operating cost and after-sales service: X40 consumables and spare parts are expensive and service response is slow, raising overall operating cost and downtime risk. 4. Limited installation space: the installation area is narrow, so new equipment must be compact and space-saving. Customer needs and solution: 1. Compliance and environmental friendliness: the equipment must run stably and comply with national and industry regulations. The zero-consumables design has no chemical emissions and meets green production requirements. 2. Coding quality and adaptability: the system must adapt to film of multiple sizes and print precisely in the designated position, with clear, high-adhesion and rub-resistant marks that stay durable and traceable. 3. Defect detection and linked control: if the coder is abnormal or a code is missed, blurred, missing or wrong, the system must detect it in real time, output an error signal to the packaging machine and reject automatically. 4. Full automation: coding, inspection and packaging run in a fully automatic linked flow, minimizing manual intervention and improving continuity and stability. 5. Service and technical support: responsive after-sales service for fast troubleshooting, plus long-term technical support and spare parts supply. DIKAI coding solution: 1. System composition: integrated laser coding plus vision inspection delivers efficient, permanent marks and closed-loop quality control through online vision inspection. 2. Laser selection: continue with the DLU500X laser system, already proven in other workshops for stability and environment adaptability. A 70mm x 70mm field lens enables embedded installation in the tight space while keeping the marking range and accuracy. 3. Vision selection: the Keyence IV4 smart vision system is compact with built-in AI learning and strong anti-interference for long-term stable operation. 4. Installation structure: custom brackets and control cabinet made to the actual site dimensions fully use existing space without extra floor area or large-scale renovation. Project highlights: 1. DIKAI lasers are widely used in the pharmaceutical industry. 2. With the DIKAI vision system, 100% online monitoring of coding quality is achieved. 3. Deep linkage of coding, inspection and packaging builds a fully automatic closed loop that reduces manual intervention and improves line efficiency.
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Project introduction: The dairy company's ice cream line runs Gempack 9-lane packers. TTO thermal transfer coders are required to code on the outer film position. Based on the customer's needs, DIKAI proposed this TTO solution. Customer needs and solution: The customer has several packers, each with 12 lanes, 9 of which are the ice cream forming end where TTO coders must be installed. Operation requirements: 1. Parameters can be edited directly on the computer without opening each cabinet. 2. The 9 coders support one-click start, one-click pause and one-click file changes. 3. The software shows ribbon remaining percentage and print status at a glance so operators can change ribbons and handle alarms in time. Solution: 1. Two packers get TTO coders on lanes 1-9, and the other packer gets TTO coders on lanes 4-12. Odd lanes use right-hand TTO machines and even lanes use left-hand TTO machines. 2. One external computer display centrally controls all 9 machines. 3. The software is customized to solve coder operation issues. 4. The 9 control boxes are integrated into one cabinet, connected with 5m or 5m+3m cables. Machines are installed according to site conditions, encoders are mounted on the upper black rubber roller, and the signal is taken from the packer cutter signal. Training: Every on-duty staff member learns to operate and maintain the machines. Open the software and click "Printer Management". Picture 1 and Picture 2 represent the lane machines and must correspond. Picture 2 is the coder network settings, where the setting marked 4 must match the setting marked 3 in Picture 1. After adding successfully, the machine runs normally.
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