Solution for the producer of light fittings that protect the product during production, tests and transportation
One of our recent interesting implementations were labels that protect lamps during internal tests and transportation. The implementation was done for the Hungarian branch of the company that is a global leader in light fitting.
The client struggled with the problem of lamps getting scratched. Light fittings were exposed to scratches and dust during production process, internal tests, and later also during transportation. The client attempted to deal with the problem on his own, but to no avail.
How were we working with the client to solve the problem? R&D cooperation.
At the beginning, we received a preview image together with the information regarding the expectations. Initially, the client suggested that we should make the protective cover consisting of two elements: a ring made of polyurethane lagging and a transparent film stuck on it. Such cap was supposed to be fitted on the lamp body for the duration of tests and transportation, and finally disposed of. After consultation with Etisoft R&D department we realized that cutting such lagging and then sticking a transparent film on it would be a very expensive and time-consuming process.
Transparent film as protection of the element?
We suggested a green transparent film with a transparent liner. The element was made in the shape of a circle with appropriate cuts on the liner and undercuts on the edge. This enabled us to stick the film onto the edge of the lamp body, and the transparent liner inside remained stuck on the label. The elements made in such way were sent for testing.
Cooperation between R&D department and technologists gives comprehensive knowledge
When we received feedback from our client it turned out that the lamps would be tested at about 100oC (which we had not known about before). It limited our options of choosing the most suitable material and production technology. Together with the client’s technologist we developed the shape of the protective element. The only thing left was to choose the most suitable material with regard to resistance to temperature, and with appropriate adhesive. We chose a transparent-green polyester masking film with easily removable silicone adhesive. It is resistant to temperatures up to 220oC. Thanks to easily removable adhesive it was possible to unstick the label without any residue left on the surface. The liner in the middle of the label was no longer necessary contrary to the first version of the solution. It simplified the technological process and had influence on the price. In order to facilitate the unsticking of the label from the lamp body for the end user of the lamp, the adhesive on the part of the label was deactivated (“fingerlift”).
Application and functionality of the suggested solution
The suggested solution in the form of labels with regard to application and functionality proved to be successful in case of the client. As a result, we designed eight elements adjusted to various lamp dimensions.
After some time, it turned out that unsticking of labels from the liner caused delays in the client’s production. The solution was to add another perforation between labels. It enables the operator to detach each label with the liner and treat as a sheet. Additionally, we added a longitudinal undercut that facilitates the unsticking of labels from the liner which is shown in the photos below.
Solution to the problem – benefits for the client
- improvement of the sticking process (through additional undercut and perforation)
- efficient protection of the lamp during production, tests and transportation
- esthetic look of the lamp (without scratches and adhesive residue after removing the protective element)
If our solution is interesting to you or you have a similar problem – contact us.