Problem
A customer had replaced several older printers with Zebra ZT411 Industrial Printers. Their older printers were designed to print and present round labels, but the operators couldn’t achieve the same result with their new Zebra printers.
Solution
EMP Engineers utilized CAD software to design and 3D print a shorter replacement bracket. This bracket was specifically created to adjust the length of the peel and present sensor allowing for easy present and peel access.
Story
In this project, a food packaging company’s new Zebra printers couldn’t properly detect their round labels for peel-and-present functionality. By reverse-engineering the original sensor bracket, EMP engineers designed and 3D printed a custom replacement that shifted the sensor just enough to accurately detect the label edge. This small but crucial adjustment prevented misfeeds and ensured seamless label application. Additionally, EMP went an extra step and preloaded printing formats directly onto the printer, allowing it to operate as a standalone unit without needing a PC connection—streamlining the customer’s workflow. Now the operator can peal and apply the label with added efficiency and without interruptions. Proof that sometimes, the smallest modifications can have the biggest impact.
