How to Install & Commission the ZONESUN ZS-TB125 Bottom Labeling Machine

ZONESUN ZS-TB125 Automatic Flat Surface Bottom Labeling Machine

The ZONESUN ZS-TB125 is a fully automatic flat surface and bottom labeling machine designed for bottles, cosmetic boxes, and flat-bottomed containers. With PLC control, high-speed labeling at up to 150 pieces/min, and Β±1.0mm accuracy, it integrates seamlessly into your production line. This guide walks you through the complete installation and commissioning process.

πŸ‘‰ View Product Page

🎬 Commissioning Video

Watch the full commissioning and operation demo before you begin:

πŸ“¦ Step 1: Unpacking & Inspection

ZONESUN ZS-TB125 Labeling Machine
  • Remove all packaging materials and protective foam carefully.
  • Inspect the machine frame, conveyor belt, label applicator head, and PLC control panel for any shipping damage.
  • Verify all accessories are included: power cable, spare parts kit, label sensor, and operation manual.
  • Machine dimensions: ~1900 Γ— 800 Γ— 1550 mm Β |Β  Weight: ~217 kg β€” use a pallet jack for positioning.

⚑ Step 2: Electrical Connection

ZS-TB125 control panel
  • Power Supply: AC 220V, 50/60Hz, 2000W β€” connect via a qualified electrician only.
  • Ensure the main switch is OFF before making any electrical connections.
  • Ground the machine properly to prevent static discharge, which can affect label sensor accuracy.
  • Power on and verify the PLC touchscreen initializes without error codes.

🏷️ Step 3: Label Roll Loading

Label roll setup
  • Compatible label roll: inside diameter Ξ¦76mm, outside diameter up to Ξ¦280mm.
  • Mount the label roll onto the unwinding shaft and thread the label tape through the guide rollers following the routing diagram on the machine.
  • Adjust the label sensor position to align with the label gap or black mark on your label stock.
  • Set label size parameters on the PLC: label length 20–160mm, label width 6–250mm.
  • Run a manual feed cycle to confirm smooth label advance without skewing or jamming.

πŸ› οΈ Step 4: Product & Conveyor Setup

Conveyor and product setup
  • Compatible product size: 40–400mm (L) Γ— 40–100mm (W) Γ— 30–100mm (H).
  • Adjust the conveyor guide rails to match your product width β€” ensure products feed in a single file without tipping.
  • Set the conveyor speed on the PLC to match your target output rate.
  • Confirm the label applicator head height is aligned with the bottom surface of the product.

βš–οΈ Step 5: Accuracy Calibration

Labeling accuracy calibration
  • Run 10 test pieces at low speed and measure label placement position on each.
  • Adjust the label delay parameter on the PLC to shift label position forward or backward.
  • Target accuracy: Β±1.0mm β€” re-run tests until all 10 pieces are within tolerance.
  • Gradually increase speed to your target rate (up to 150 pieces/min) and re-verify accuracy at full speed.

▢️ Step 6: Trial Run & Speed Adjustment

Trial run
  • Start the machine at the lowest speed setting (25 pieces/min) for the initial trial run.
  • Observe the full labeling cycle: product feed β†’ label peel β†’ label apply β†’ product exit.
  • Check for label wrinkles, misalignment, or missed labels β€” adjust sensor sensitivity if needed.
  • Gradually increase to your target production speed once all stations are confirmed stable.

βœ… Final Checklist Before Production

  • β˜‘ All guards and safety covers are in place.
  • β˜‘ Emergency stop button is functional.
  • β˜‘ Label roll loaded and threading confirmed smooth.
  • β˜‘ Label placement accuracy within Β±1.0mm.
  • β˜‘ Conveyor guide rails adjusted to product width.
  • β˜‘ PLC parameters saved and backed up.
  • β˜‘ Operator trained on HMI controls and emergency procedures.

πŸ”§ Common Troubleshooting Tips

Issue Possible Cause Solution
Label not peeling Peeling plate angle too low / label tension wrong Adjust peeling plate angle; re-thread label tape
Label placement offset Label delay parameter incorrect Adjust label delay on PLC touchscreen
Label skewing or wrinkling Guide rollers misaligned / label roll not centered Re-center label roll; realign guide rollers
Missed labels Label sensor sensitivity too low Increase sensor sensitivity on PLC
Machine stops unexpectedly Label roll empty / sensor triggered Replace label roll; check error code on HMI

πŸ“ž Need Help?

Our technical support team is ready to assist with installation, commissioning, and after-sales service.

πŸ“§ Email: support@zonesunpro.com
🌐 Website: www.zonesunpro.com

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