{"id":56517,"date":"2026-08-20T11:42:23","date_gmt":"2026-08-20T09:42:23","guid":{"rendered":"https:\/\/smans.com\/?post_type=knowledgeportal&p=56517"},"modified":"2026-08-21T10:36:17","modified_gmt":"2026-08-21T08:36:17","slug":"integrating-wire-marking-into-the-cut-and-strip-process","status":"publish","type":"knowledgeportal","link":"https:\/\/smans.com\/en\/knowledgebase\/integrating-wire-marking-into-the-cut-and-strip-process\/","title":{"rendered":"Integrating wire marking into the cut and strip process"},"content":{"rendered":"

Automatically cutting and stripping a wire is one thing. Ensuring that the same wire is also provided with the correct identification during the production process is the next step.<\/p>\n

In many applications, these operations naturally belong together. After all, the production order determines not only the required wire length and stripping parameters, but also the identification associated with that specific wire.<\/p>\n

However, integrating wire marking involves more than simply connecting a printer to a cutting and stripping machine. The marking information needs to be linked to the correct production order, the position on the wire needs to be known, and the marking system needs to be triggered at the right moment.<\/p>\n

The key question is therefore not only how to mark a wire<\/strong>, but above all how to make marking an integral part of the wire processing workflow<\/strong>.<\/p>\n

It starts with the production order<\/h2>\n

An automated cutting and stripping machine operates on the basis of production data. The required length and stripping parameters can be defined for each wire. Marking information can also be linked to this production data.<\/p>\n

A wire list can be converted from Excel and sent directly to the machine. The production list contains the information required to produce and identify different wires.<\/p>\n

With POSSS<\/strong><\/a>, this flow of information can be further digitalised. The software provides a link between the machine and assembly and helps to logically organise, bundle and identify produced wires. This keeps the information from the production order connected to the subsequent processing and assembly of the wire.<\/p>\n

This highlights an important principle: automated wire marking starts with the data, not with the printer.<\/strong><\/p>\n

The right information also needs to be in the right place<\/h2>\n

With wire marking, much of the attention goes to the content: which number, code or text needs to be printed on the wire?<\/p>\n

In an automated process, there is a second question:<\/p>\n

Where exactly should that information be placed?<\/strong><\/p>\n

Suppose a wire needs to be marked at a specific distance from the end. During transport, the machine needs to know when that position reaches the marking station.<\/p>\n

Several elements need to work together:<\/p>\n

    \n
  • the production data determines what needs to be marked;<\/li>\n
  • the configured position determines where the marking should be placed;<\/li>\n
  • the length measurement tracks how much wire has passed through the machine;<\/li>\n
  • the machine triggers the marking system at the right moment.<\/li>\n<\/ul>\n

    Positioning is therefore not an isolated detail of the printing system. It is part of the complete wire processing workflow.<\/p>\n

    And that is precisely the difference between a printer positioned next to a machine and a marking system that is truly integrated into the production process.<\/p>\n

    Printing directly onto the wire with inkjet<\/h2>\n

    \"\"One way to automate wire marking is direct inkjet printing.<\/p>\n

    The wire passes the printhead and is printed during the production process. The connected control system determines which information needs to be printed and when the print command is executed.<\/p>\n

    The process advantage is clear: the identification is printed directly onto the wire, without the need to apply a separate label or other identification component.<\/strong><\/p>\n

    Because printing can take place inline during the cutting and stripping process, there is no need for a separate marking step and the wire can continue through the process without an additional intermediate operation.<\/p>\n

    Different wire diameters require attention<\/h3>\n

    For good print quality, the wire needs to be guided correctly in relation to the printhead.<\/p>\n

    This becomes relevant when different wire diameters are processed on the same installation. When changing diameter, the wire guidance may need to be adjusted.<\/p>\n

    The practical question when considering automation is therefore not only how many different wires a machine can process, but also:<\/p>\n

    What still needs to be physically adjusted between two jobs?<\/strong><\/p>\n

    Marking information and other production parameters can be changed digitally. A different wire diameter, on the other hand, may require a mechanical adjustment.<\/p>\n

    For companies processing a wide variety of production jobs, this is an important distinction.<\/p>\n

    Ink selection also affects production<\/h2>\n

    Another practical consideration with inkjet printing is the ink itself.<\/p>\n

    Replacing a cartridge with the same type of ink is different from switching to another ink type. When making such a change, the ink still present in the system needs to be taken into account.<\/p>\n

    Choosing an inkjet solution therefore involves more than simply determining whether the required text can be printed on the wire.<\/p>\n

    The production pattern matters as well.<\/p>\n

    Do you work with the same configuration for long periods? Or do you regularly switch between wires and applications that require different settings or consumables?<\/p>\n

    The greater the variation in production, the more important the changeover between jobs becomes.<\/p>\n

    Automatically applying a wrap-around label<\/h2>\n

    \"\"Not every type of identification needs to be printed directly onto the wire.<\/p>\n

    Another option is a wrap-around label. The identification is first printed onto a label, which is then applied around the wire.<\/p>\n

    A self-laminating wrap-around label consists of a printable section and a transparent section. When the label is wrapped around the wire, the transparent section covers the printed information.<\/p>\n

    Printing and application can be performed manually, but the process can also be automated.<\/p>\n

    In an automated setup, the wire is positioned in the system, after which the label is printed and applied around the wire.<\/p>\n

    A sleeve as a third option<\/h2>\n

    In addition to direct printing and wrap-around labels, a wire can also be identified using a sleeve<\/strong>. The identification is printed on the sleeve, which is then positioned around or over the wire.<\/p>\n

    Depending on the application, this can be done manually or automatically<\/strong>. For higher volumes, automated processing can be an interesting way to integrate sleeve application further into the production process. For smaller batches or applications with a high degree of variation, manual processing may be a logical choice.<\/p>\n

    As with a wrap-around label, a sleeve adds a physical identification element to the wire. You therefore also need to consider when the sleeve is applied and which operations the wire still needs to undergo afterwards.<\/p>\n

    With labels and sleeves, their position in the process also matters<\/h2>\n

    With direct inkjet printing, the information is applied directly to the wire. With a wrap-around label or sleeve, a physical element is added.<\/p>\n

    This difference is important when designing the production line.<\/p>\n

    You need to determine not only where on the wire<\/strong> the identification should be located, but also when in the production process<\/strong> it should be applied.<\/p>\n

    This is particularly relevant when the wire still needs to pass through other processing steps or machine components afterwards.<\/p>\n

    Label or sleeve application should therefore not be considered separately from the rest of the production line. The complete route the wire follows needs to be taken into account.<\/p>\n

    This leads to a simple but important process question:<\/p>\n

    Which operations still need to take place after the wire has been marked?<\/strong><\/p>\n

    The answer helps determine where the marking operation should best be positioned within the process.<\/p>\n

    Inkjet, wrap-around label or sleeve? Start with your process<\/h2>\n

    Direct inkjet printing, wrap-around labels and sleeves can all provide the required wire identification, but they affect the production process differently.<\/p>\n

    With inkjet, the information is printed directly onto the moving wire.<\/strong> Marking can take place inline, so the production line does not need to stop for this operation.<\/p>\n

    With a wrap-around label, the wire needs to stop while the label is applied.<\/strong> This adds to the cycle time. In addition, a physical label is added that needs to remain correctly positioned during subsequent wire processing.<\/p>\n

    With a sleeve, identification is provided by a separate element placed around or over the wire.<\/strong> This can be done manually or automatically, so the impact on the production process depends strongly on the chosen application method.<\/p>\n

    The most suitable technology is not determined by speed alone.<\/p>\n

    Start by asking a number of practical questions:<\/p>\n

      \n
    • Which wires and wire diameters do you process, and how often does your production change?<\/strong><\/li>\n
    • What information needs to be applied and where should the identification be positioned?<\/strong><\/li>\n
    • What requirements does the end customer set for identification, legibility and durability?<\/strong><\/li>\n
    • Which standards or regulations must the wire identification comply with?<\/strong><\/li>\n
    • How do inkjet printing, wrap-around labels or sleeves affect cycle time, changeovers and subsequent processing?<\/strong><\/li>\n<\/ul>\n

      This way, the technology becomes a consequence of the application rather than the starting point.<\/p>\n

      Don’t overlook changeover time<\/h2>\n

      When discussing automation, the focus quickly shifts to cycle time. How quickly can a wire be produced? How quickly can the marking be applied?<\/p>\n

      But when processing many different jobs, cycle time does not tell the whole story.<\/p>\n

      Between two production jobs, for example, a different wire may need to be loaded, the guidance adjusted and a new production program selected.<\/p>\n

      It is therefore useful to distinguish between two types of changes when evaluating a marking process.<\/p>\n

      Digital changes<\/strong> are parameters that can be modified through the production order, such as the marking information.<\/p>\n

      Physical changeovers<\/strong> require an intervention on the installation, for example because a different wire diameter requires an adjustment to the guidance or because another type of identification material needs to be used.<\/p>\n

      How significant these changeovers are depends on your product mix. A production environment with long runs has different requirements from one processing many different wire types in small batches.<\/p>\n

      Does wire marking always need to be integrated?<\/h2>\n

      No.<\/p>\n

      A separate marking step can be perfectly suitable for a production environment with limited volumes or for a process where full integration offers little benefit.<\/p>\n

      The same applies to sleeves. Depending on volumes, variation and the application, manual processing can remain a logical choice.<\/p>\n

      The relevant question is therefore not whether integrated wire marking is technically possible, but whether it fits the way you produce<\/strong>.<\/p>\n

      Integration becomes particularly worth investigating when cutting and stripping are already automated, identification is a recurring production step and the required marking information is digitally available.<\/p>\n

      Start by mapping the current workflow.<\/p>\n

      Where does the marking information come from? Who enters it? When is the marking applied? Which operations are required? How often does production change? And which information is already available to the cutting and stripping machine?<\/p>\n

      Only then can you determine which step you actually want to automate.<\/p>\n

      Good wire marking starts before the marking station<\/h2>\n

      Automated wire marking does not start with the choice of an inkjet printer, label applicator or sleeve solution.<\/p>\n

      It starts with the production order.<\/p>\n

      The marking information needs to belong to the correct wire. The required position needs to be known. The machine needs to know when that position reaches the marking station. And the selected marking method needs to fit what happens to the wire before and after that step.<\/p>\n

      In addition, end-customer requirements, applicable standards and regulations<\/strong> may also determine which identification method is suitable.<\/p>\n

      Once these conditions are clear, the choice between direct inkjet printing, a wrap-around label and a sleeve<\/strong> becomes much more concrete.<\/p>\n

      Start by looking at the complete flow from production data to finished wire. Only then consider the technology required to achieve it.<\/strong><\/p>\n

      Automating wire marking in your production?<\/h2>\n

      Would you like to determine where wire marking fits best within your current cutting and stripping process? Smans can work with you to assess your wire types, production data, required identification, application requirements and existing production setup.<\/p>\n

      This way, you do not start from an individual machine or marking technology, but from what your production process actually requires.<\/p>\n","protected":false},"featured_media":56515,"template":"","class_list":["post-56517","knowledgeportal","type-knowledgeportal","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"\nIntegrating wire marking into the cut and strip process - Smans<\/title>\n<meta name=\"description\" content=\"How do you automate wire marking during cutting and stripping? 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