Automatic high speed labeling system

An automatic, high speed produce labeler capable of applying labels of different sizes, wherein said labeler includes a rotary head carrying a plurality of flexible bellows, a removable label cassette carrying a label carrier strip wherein a stepper motor actuates a direct gear drive train connected to and driven by said stepper motor, wherein a Geneva wheel assembly is connected to and driven by said first direct gear drive train and wherein a label cassette is connected to and driven by said Geneva wheel assembly, characterized by:

• said label cassette having a quick change drive pulley, scallop wheel and drive belt,
• said first and second gear drive trains and said Geneva wheel assembly operate at high speed to dispense and apply 1,000 labels per minute to produce items in a single lane,
• whereby said quick-change drive pulley, scallop wheel and drive belt of said label cassette allows said apparatus to be capable of being adapted to apply different size labels without having to stop operation of said rotary head, and
• wherein said Geneva wheel assembly includes an input and output wheel, and said wheels are sized and placed so that said output wheel is rotated through at least a ninety degree arc for each label dispense cycle.

A method of automatically applying labels to 1,000 produce items per lane per minute, wherein said labeler includes a rotary head carrying a plurality of flexible bellows, a removable label cassette carrying a label carrier strip, a stepper motor, a first direct gear drive train connected to and driven by said stepper motor, a Geneva wheel assembly including an input wheel and an output wheel connected to and driven by said first direct gear drive train, said label cassette connected to and driven by said Geneva output wheel, a second direct gear drive train connected to and driven by said stepper motor, said rotary head connected to and driven by said second gear drive train comprising the steps:

• causing said stepper motor to rotate through index steps wherein each index step is a label dispense cycle lasting less than 17 milliseconds,
• transferring each said rotary index step of said stepper motor through said first direct gear drive train to rotate said Geneva input wheel,
• said Geneva input drive wheel causing said Geneva output wheel to rotate through an arc of at least 90 degrees for each said label dispense cycle,
• said Geneva driven wheel causing said label carrier strip to advance a distance equal to the length of a label to be applied in each label dispense cycle,
• wherein for each label dispense cycle of less than 17 milliseconds said Geneva driven wheel imparts at least 40% reduced jerk of said label carrier strip at the beginning of each label dispense cycle compared with the prior art, thereby minimizing the tearing or slipping of said label carrier strip and facilitating the dispensing and application of 1,000 labels per minute for a single rotary head.