How to Install & Commission the ZONESUN ZS-TB125 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 ±1.0mm accuracy, it integrates seamlessly into your production line. This guide walks you through the complete installation and commissioning process.
🎬 Commissioning Video
Watch the full commissioning and operation demo before you begin:
📦 Step 1: Unpacking & Inspection
- 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 × 800 × 1550 mm | Weight: ~217 kg — use a pallet jack for positioning.
⚡ Step 2: Electrical Connection
- Power Supply: AC 220V, 50/60Hz, 2000W — 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
- Compatible label roll: inside diameter Φ76mm, outside diameter up to Φ280mm.
- 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.
🛠️ Step 4: Product & Conveyor Setup
- Compatible product size: 40–400mm (L) × 40–100mm (W) × 30–100mm (H).
- Adjust the conveyor guide rails to match your product width — 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.
⚖️ Step 5: 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: ±1.0mm — 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
- Start the machine at the lowest speed setting (25 pieces/min) for the initial trial run.
- Observe the full labeling cycle: product feed → label peel → label apply → product exit.
- Check for label wrinkles, misalignment, or missed labels — adjust sensor sensitivity if needed.
- Gradually increase to your target production speed once all stations are confirmed stable.
✅ Final Checklist Before Production
- ☑ All guards and safety covers are in place.
- ☑ Emergency stop button is functional.
- ☑ Label roll loaded and threading confirmed smooth.
- ☑ Label placement accuracy within ±1.0mm.
- ☑ Conveyor guide rails adjusted to product width.
- ☑ PLC parameters saved and backed up.
- ☑ Operator trained on HMI controls and emergency procedures.
🔧 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 |
📞 Need Help?
Our technical support team is ready to assist with installation, commissioning, and after-sales service.
📧 Email: support@zonesunpro.com
🌐 Website: www.zonesunpro.com