U.S. patent application number 10/085601 was filed with the patent office on 2002-08-29 for customized prescription product packaging and method and system for producing customized prescription product packaging.
Invention is credited to Beaton, Stephen R., Duis, Donnie Jerome, Himes, George E., Martin, Wallace Anthony, Wang, Daniel Tsu-Fang.
Application Number | 20020117405 10/085601 |
Document ID | / |
Family ID | 23966273 |
Filed Date | 2002-08-29 |
United States Patent
Application |
20020117405 |
Kind Code |
A1 |
Wang, Daniel Tsu-Fang ; et
al. |
August 29, 2002 |
Customized prescription product packaging and method and system for
producing customized prescription product packaging
Abstract
This invention provides packaging for housing at least one
prescription product comprising customized graphics on at least
some surface area of said packaging, said customized graphics being
selected by the individual doctor prescribing said prescription
product or the patient to receive said prescription product. This
invention further provides the method and system for producing
customized packaging which houses at least one prescription
product, wherein said packaging is customized by the individual
doctor prescribing and/or said patient receiving said at least one
prescription product comprising the steps of: receiving an order
for at least one prescription product from said doctor or a refill
order from said patient; and printing out customized graphics
specified by said doctor or said patient for said package for at
least one prescription product.
Inventors: |
Wang, Daniel Tsu-Fang;
(Jacksonville, FL) ; Beaton, Stephen R.;
(Jacksonville, FL) ; Himes, George E.;
(Jacksonville, FL) ; Martin, Wallace Anthony;
(Orange Park, FL) ; Duis, Donnie Jerome;
(Jacksonville, FL) |
Correspondence
Address: |
AUDLEY A. CIAMPORCERO JR.
JOHNSON & JOHNSON
ONE JOHNSON & JOHNSON PLAZA
NEW BRUNSWICK
NJ
08933-7003
US
|
Family ID: |
23966273 |
Appl. No.: |
10/085601 |
Filed: |
February 27, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10085601 |
Feb 27, 2002 |
|
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09494859 |
Feb 1, 2000 |
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Current U.S.
Class: |
206/5.1 ;
206/459.5 |
Current CPC
Class: |
B65D 5/4216 20130101;
B65B 25/008 20130101 |
Class at
Publication: |
206/5.1 ;
206/459.5 |
International
Class: |
A45C 011/04 |
Claims
We claim:
1. Packaging for housing at least one prescription product
comprising customized graphics on at least some surface area of
said packaging, said customized graphics being selected by the
individual doctor prescribing said prescription product or the
patient to receive said prescription product.
2. The packaging of claim 1 wherein said customized graphics are
specified at the time an order for said prescription product is
placed.
3. The packaging of claim 1 wherein the customized graphics
identifies the person for whom the prescription product is for.
4. The packaging of claim 3 wherein said packaging does not
identify the prescription.
5. The packaging of claim 1 wherein the customized graphics
identifies said doctor prescribing said prescription product.
6. The packaging of claim 1 wherein said prescription product is
shipped from the manufacturer having said customized graphics on
said packaging.
7. The packaging of claim 1 wherein said packaging comprises
primary packaging and secondary packaging and said customized
graphics are present on at least some surface area of said primary
packaging or said secondary packaging.
8. The packaging of claim 7 wherein said customized graphics are
present on at least some surface area of said primary
packaging.
9. The packaging of claim 1 wherein said prescription product is a
contact lens.
10. The packaging of claim 9 wherein said packaging comprises
primary packaging and secondary packaging and said customized
graphics are present on at least some surface area of said primary
packaging.
11. The packaging of claim 10 wherein said primary packaging is a
blister pack comprising a bowl and lidstock, wherein said
customized graphics is present on said lidstock.
12. The packaging of claim 11 wherein said graphics are printed
onto said lidstock.
13. The packaging of claim 11 wherein said graphics are printed
onto a label which is adhered to said lidstock.
14. The packaging of claim 9 wherein said packaging comprises
primary packaging and secondary packaging and said customized
graphics are present on at least some surface area of said
secondary packaging, said secondary packaging being a carton.
15. The packaging of claim 14 wherein said customized graphics are
printed onto said carton.
16. The packaging of claim 14 wherein said graphics are printed
onto a label which is adhered to said carton.
17. The packaging of claim 1 wherein said graphics comprise
alphanumeric characters.
18. The packaging of claim 1 wherein said graphics comprise
pictures.
19. The method of producing customized packaging which houses at
least one prescription product, wherein said packaging is
customized by the individual doctor prescribing and/or said patient
receiving said at least one prescription product comprising the
steps of: receiving an order for at least one prescription product
from said doctor or a refill order from said patient; and printing
out customized graphics specified by said doctor or said patient
for said package for at least one prescription product.
20. The method of claim 19 wherein said printing step entails
printing said customized graphics on primary packaging for said
prescription product.
21. The method of claim 19 wherein said printing step entails
printing said customized graphics on secondary packaging for said
prescription product.
22. The method of claim 19 wherein said printing step entails
printing said customized graphics onto a label.
23. The method of claim 22 further comprising the step of
varnishing the label.
24. The method of claim 22 wherein after said printing step the
method further comprises the step of adhering said label onto said
packaging.
25. The method of claim 19 wherein the prescription product is a
contact lens.
26. The method of claim 22 wherein said label has a label
identification means.
27. The method of claim 26 wherein said packaging has a product
machine readable code, and said method further comprises the step
of checking said label identification means and said product
machine readable code before said adhering step.
28. The method of claim 27 wherein said method further comprises
the step of picking said prescription product in customary
packaging from inventory and diverting it to a customized graphics
printing system prior to said checking step.
29. The method of claim 19 wherein said printing step is performed
by a customized graphics printing system.
30. A customized graphics printing system for adding customized
graphics to packaging for a prescription product comprising: a
computer for receiving order information for a prescription product
and for the customized graphics to be printed on the packaging for
said prescription product; and a printer for printing out said
customized graphics for said packaging for said prescription
product.
31. The system of claim 30 further comprising a varnishing
application apparatus for applying varnish to said packaging.
32. The system of claim 30 wherein said customized graphics is
printed on a label, and each label has a unique identification
means.
33. The system of claim 32 wherein each of said labels is for a
particular ordered prescription product, and said system matches up
said prescription product with said label.
34. The system of claim 30, further comprising a quality check
station.
35. The system of claim 33, further comprising a label applicator.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to customized prescription
product packaging, and the method of producing customized
prescription product packaging.
BACKGROUND OF THE INVENTION
[0002] The packaging of contact lenses is well known in the contact
lens manufacturing technology. For short-term use or single wear
contact lenses, such packaging arrangements generally consist of
blister packs which are employed for the storage and dispensing of
the hydrophilic contact lenses by a medical practitioner or sale to
a patient who wears the contact lenses. Typically, the blister
packs have a plastic bowl shaped area to receive the contact lens
and aqueous solution, and a cover, such as a heat-sealed lidstock
which may consist of one or more polymeric or foil layers. Several
blister packs may be removably attached to each other usually by
the lidstock to form an array of blister packs. An example of a
blister pack which is adapted to provide a sterile sealed storage
environment for a disposable or single-use hydrophilic contact
lens, wherein the lens is immersed in a sterile aqueous solution is
described in U.S. Pat. No. 4,691,820 to Martinez; which is assigned
to the common assignee of the present invention, and the disclosure
of which is incorporated herein by reference.
[0003] Typically, one or more of the arrays of blister packs are
placed in a box or carton for sale to the patient. Conventionally,
the pluralities of blister packs containing the contact lenses in
the sterile aqueous solutions are packaged and stored in cartons
each containing a specified quantity of the blister packs; for
example, 15 or 30 blister packs or other suitable quantities.
Generally, the cartons are constituted of cardboard or paperboard
possessing rectangular configurations and are imprinted in one or
more colors with suitable identifying legends, logos, decorative
indicia and/or instructions in the use of the contents, and
information regarding the manufacturer, as may be required by
various government regulations and/or statutes.
[0004] The cartons are usually placed in large storage boxes
proximate the manufacturing lines where the lenses were produced,
packaged, and sterilized. The large storage boxes containing the
cartons are forwarded to distribution centers or warehouses and
stocked at those locations. In the event that no further processing
of the carton contents is required, upon the receipt of shipping
and/or sales orders, the large storage boxes are eventually pulled
from stock, the cartons containing the product, such as the
blister-packaged contact lenses, are removed from the boxes,
separated into individual orders which may consist of various
different products, and the orders shipped to prospective
customers, such as domestic or foreign distributors, physicians,
optometrists or to potential users of the contact lenses.
[0005] Both the lidstock and the cartons may contain some
information which is printed upon the lidstock or carton just prior
to the time that the lidstock is sealed onto the blister or just
prior to the time that the arrays of blister packs are placed in
the cartons. The information which is added to the lidstock or the
carton at this time typically is limited to the power, axis,
cylinder, expiration date and lot number. All the other information
and logos are usually present on the lidstock and cartons prior to
packaging the contact lenses in the manufacturing line.
SUMMARY OF THE INVENTION
[0006] This invention provides packaging for housing at least one
prescription product comprising customized graphics for said
packaging, said graphics are customized by the individual doctor
prescribing and/or the individual patient receiving said at least
one prescription product.
[0007] This invention further provides the method and system for
producing customized packaging which houses at least one
prescription product, wherein said packaging is customized by the
individual doctor prescribing and/or said patient receiving said at
least one prescription product, said method comprising the steps
of:
[0008] receiving an order for at least one prescription product
from said doctor or a refill order from said patient; and
[0009] printing out customized graphics specified by said doctor or
said patient for said package for at least one prescription
product.
[0010] This invention provides packaging and a method and system
for producing customized packaging for said at least one
prescription product. The benefit of this invention is to provide
the doctors with the ability to customize the prescription product
packages for his or her patients. The doctor can add his or her
name, telephone number(s), e-mail address, website, street address,
appointment information, greetings, a picture of the doctor,
office, local landmark, and/or any other desired picture or
information directly to the packaging materials for the
prescription product. The preferred prescription product is a
contact lens. This invention is particularly beneficial for doctors
to provide cartons having customized graphics to new patients who
may have been fitted with trial pairs of contact lenses and must
return to the doctor for a follow-up appointment. It also provides
a vehicle for the doctors to advertise their practices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Reference may now be had to the following detailed
description of the preferred embodiments of the invention, taken in
conjunction with the accompanying drawings; in which:
[0012] FIG. 1 illustrates a perspective top and side view of a
blister pack array with customized graphics;
[0013] FIG. 2 illustrates a perspective top and side view of a
carton with customized graphics;
[0014] FIG. 3 illustrates a top view of an insert with customized
graphics;
[0015] FIG. 4 illustrates a top view of a label having customized
graphics for a carton; and
[0016] FIG. 5 is a schematic of a top view of a system for printing
out labels having customized graphics for adhering to a carton.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The invention will be described for the preferred
prescription product, a contact lens; however, any prescription
product could be substituted for the contact lens. Examples of
other prescription products include medications, spectacles,
medical devices, or the like.
[0018] The "identification means" is a number, bar-code,
two-dimensional matrix, three dimensional matrix, inductive
transmitting/receiving device, or radio frequency chip, or the
like. Preferably each identification means contains some unique
information for every part having one. Identification means may be
machine readable and/or human readable, preferably at least machine
readable. A machine readable identification means preferably has
information stored in a database associated with the identification
means. For packaging, the information stored in the database
associated with the identification means may not be present on the
packaging in human-readable form. That is, the only way to know
which product is in the packaging is to access the information in
the database by inputting the identification means into the
database, via a bar-code reader or the like.
[0019] As shown in FIGS. 1, 2, and 3 the packaging having
customized graphics which houses at least one contact lens can be
part of any of the packaging for the contact lens. Typically,
contact lens packaging comprises primary packaging and secondary
packaging. The primary packaging is the packaging adjacent to the
contact lens, the secondary packaging surrounds the primary
packaging. There can be any number of layers of packaging for the
contact lens; however, in the preferred embodiment, there is
primary packaging and secondary packaging. The customized graphics
can be added to the primary, and/or secondary packaging and/or it
can be a package insert, typically placed within the secondary
packaging. The customized graphics can be an alphanumeric message,
picture, photograph, and/or the like, or combinations of the
above.
[0020] The primary packaging for a contact lens is preferably a
blister pack with a lidstock, but it can take any form, e.g. a
glass bottle, cans, trays, pouches, e.g. form-fill-and-seal
pouches, as long as it provides adequate protection for the contact
lens. FIG. 1 shows a blister pack array 10 having customized
graphics. The blister pack array 10 consists of five blister 204;
packs 11. Each blister pack 11 consists of an individual base 12
all five of which are interconnected by a contiguous lidstock 13,
which is scored so that the individual blister packs 11 can be
detached from the array 10. Each base 12 preferably comprises
injection-molded or thermoformed plastic incorporating a molded
cavity 15 which is surrounded by an outstanding planar flange 18
about the rim of the cavity 15. A flexible cover sheet or lidstock
13 is adhered to the surface of the flange 18 so as to sealingly
enclose the cavity 15 in a generally air and liquid-tight mode.
Within the cavity 15 of the base portion, a contact lens (not
shown) is immersed in a sterile aqueous solution (not shown).
Preferably the contact lens is a hydrophilic contact lens
manufactured of materials known to those of ordinary skill in the
art. The customized graphics 14 shown are present on the lidstock
13 and indicate the patient to receive the contact lens in each
blister pack, and which eye of the patient the contact lens should
be placed in. The customized graphics 14 state on the lidstock for
each blister pack: "CONTACT LENS FOR JOAN'S LEFT EYE". There may be
no prescription information e.g. power for spherical contact lenses
or power, cylinder, axis for toric contact lenses present on the
packaging, only information indicating who the product is for, and
directions for its proper use. The packaging may only be identified
and tracked by the manufacturer by at least one identification
means, also referred to as a product identification means,
preferably a machine readable identification means present on the
packaging, preferably on at least the secondary packaging, more
preferably present on both the primary packaging and secondary
packaging for contact lenses. The information associated with the
product identification means, such as, SKU, lot number, expiration
date, can be stored in one or more databases. The information is
accessible when the product identification means is inputted into a
computer, which can access the database.
[0021] Presently, it is preferred that the packaging for the
contact lenses comprise primary and secondary packaging. The
preferred secondary packaging is a carton, but it can take any
form, such as, bags, plastic wraps, envelopes, pouches, cans,
boxes, bottles, or trays. The secondary packaging preferably houses
multiple primary packages. The preferred secondary packaging is
shown in FIG. 2. FIG. 2 shows a carton 20, which preferably houses
multiple contact lenses each in primary packaging (such as one more
of the arrays shown in FIG. 1). The rectangular carton 20
preferably comprises paperboard. The carton 20 includes flat top
wall panel 21 and opposing bottom wall panel (not shown) respective
front panel 25 and opposing rear panel (not shown), and opposite
end walls 24 (only one shown) which are sealed through an adhesive
or glued construction as is known in the carton forming technology.
The top wall panel 21 includes a downwardly depending front flap 26
having a centrally located latching tab 27 at a lower edge thereof
which is adapted to be tucked into a cooperating latching slit (not
shown) centrally formed in the front panel 25 to facilitate
reclosing of the carton 20. The top wall panel 21 is adapted to be
swung upwardly about a rear hinge line 28 to open the carton 20.
The top wall panel 21 of the carton is shown having the customized
graphics 22, 23 which consist of alphanumerics 22 and a picture 23.
The alphanumerics 22 state: "CONTACT LENSES FOR JOAN SMITH PROVIDED
BY DR. JONES". The picture 23 is a photograph of the doctor, Dr.
Jones, who prescribed the contact lenses.
[0022] FIG. 3 shows a third embodiment of the invention in which
the customized graphics are added to a package insert. The package
insert can be a paper or any object, e.g. a toy, a mirror, etc.,
which is added to the packaging. FIG. 3 shows the insert 30 as a
piece of paper, and the customized graphics 31 is an alphanumeric
message which states: "These contact lenses are provided to Joan
Smith by DR. JONES, O.D. Our office will call you in one month to
schedule a follow-up. In the interim if you have any problems with
these contact lenses, please call my office at 555-5555. Your eyes
are important to me." The package insert paper 30 can be folded up
to fit into the secondary packaging, e.g. carton. The customized
graphics shown in the figures are exemplary. Any alphanumeric
message, picture, or photograph selected by the doctor, or patient
could be used.
[0023] FIG. 4 shows a label 40. The label may be adhered to blank
areas of the packaging or it may be an over-label, meaning it may
be adhered to areas of the packaging which are partially or fully
labeled for distribution. The label 40 is preferably an adhesive
sticker. The label 40 as shown is shaped for use on a carton
similar to the carton shown in FIG. 2. The label 40 consists of a
top layer 47 comprising paper, polymer, (e.g. polyvinylchloride
film) or metal film, preferably paper. Preferably there is an
adhesive layer (not shown) coated on the back side of the top layer
47. The label 40 may be attached to a peel layer (not shown) which
the top layer 47 and the adhesive layer can be peeled from before
attaching the label 40 to the package. Preferably, the adhesive is
a permanent adhesive, e.g. Avery Dennison adhesive LP-430
Permanent/Emulsion Acrylic with service temperature range -54 to
+93.degree. C.; Avery Dennison adhesive S-4600 Permanent/Acrylic
with service temperature range -40 to +80.degree. C. Alternatively,
the label 40 may only consist of a top layer 47 and the adhesive
can be applied to the packaging before the top layer is applied to
the packaging. The label 40 has multiple types of customized
graphics 41, 42, and 43. The label 40 has a doctor's photograph 41,
a picture of a sail boat 42, and an alphanumeric message 43
indicating that the contact lenses are "Provided by Dr. Sailor
(555) 555-5555". The photograph, picture and alphanumeric message
are all selected by the doctor. The doctor could specify (or a
patient may select) a picture which he/she knows is well suited for
a patient, e.g. a horse for a horse-lover.
[0024] As shown in FIG. 4, the label may comprise additional
information such as a product identification means 45, and a label
identification means 46, preferably both identification means are
machine-readable identification means. The product identification
means 45 is used to identify the type of the contact lenses and the
prescription of the contact lenses that are within the carton to
which the label 40 is to be adhered to. The optional label
identification means 46 can be used to identify the specific label
40, so that it can be tracked on and off the carton, so that the
label is put on the correct carton, and so the product is sent to
the proper recipient, either the patient or the doctor. Also, in
the preferred embodiment, the label identification means is used
through the customized graphics printing system for tracking the
quality of the label. Alternatively, the label identification means
46 may be in a portion of the top layer 47 of the label which stays
with the peel layer when the top layer 47 is removed from the peel
layer, preferably just before adhering the label to the correct
carton.
[0025] Also alternatively, the product identification means 45 may
not be on the label and is present instead on an area of the
packaging which is not covered when the label 40 is put on the
packaging. If the label identification means is not present on the
label the order information can be associated with the product
identification means in the database and the product identification
means can be used to track the packaging after the label is adhered
to the packaging. Alternatively, the label identification means can
be product identification means if the label identification means
is the only identification means present on the packaging.
[0026] The label 40 is shown having some standard graphics 44 which
are not customized for either the doctor and/or the patient and may
be present on the label 40 before (or added to the label 40 after)
the customized graphics are printed onto the label 40, or the
non-customized graphics can be printed onto the label 40 at the
same time that the customized graphics are added. In short, the
customized and non-customized graphics can be added to the
packaging in any sequence. Non-customized information includes,
e.g., identifying legends and logos pertaining to the company
manufacturing and/or marketing the product, instructions pertaining
to the use of the product packaged in the carton, decorative
indicia the contents, directions for use, warnings about dispensing
the prescription product without a prescription, and the like.
[0027] If the customized graphics are added to the primary package
and the primary package comprises a blister pack comprising a bowl
and lidstock, it is presently preferred that the customized
graphics are added to the lidstock. Either the lidstock can be
printed on directly to add the customized graphics or the
customized graphics can be added indirectly to the lidstock by
printing out a label having customized graphics and adhering the
label to the lidstock. Alternatively, a label having a blank area
can be adhered to the lidstock and printed on after adhering to the
lidstock. The preferred methods for printing out customized
graphics on labels will be described in more detail below. (The
preferred method described below is presently used to print out
labels for cartons, but it can be modified to print out labels for
lidstock, instead.) In the embodiment shown in FIG. 1, the
customized graphics 10 were added to the lidstock 13 directly by
printing onto the lidstock. Either an area on the lidstock can be
reserved for the customized graphics or the customized graphics can
cover the entire lidstock.
[0028] It is presently preferred that the customized graphics are
added to the secondary packaging. Presently the preferred secondary
packaging is a carton. The customized graphics can be added to
either the outside or inside surface area of the secondary
packaging. The customized graphics are preferably present on at
least 5 percent of the outside surface area of the secondary
packaging, more preferably at least up to 25 percent, and most
preferably at least 50 percent of the outside surface area of the
secondary packaging. Preferably the customized graphics comprise a
background image which is present on at least 30 percent, more
preferably at least 60 percent and most preferably at least 80
percent of the surface area of the secondary packaging. For a
carton, preferably, at least one panel or wall has some customized
graphics, more preferably at least two panels have some customized
graphics, most preferably at least three panels have some
customized graphics. Alternatively or in addition to the customized
graphics on the outside surface of the secondary packaging, the
customized graphics can cover a portion of the inside surface area
of the secondary packaging. Presently, it is preferred that the
outside surfaces of the secondary packaging carry the customized
graphics.
[0029] The customized graphics can be added to the secondary
packaging either directly or indirectly. The secondary packaging
can be printed on directly or a label may be adhered to the
secondary packaging and then printed upon. For indirect printing,
the customized graphics can first be printed onto a label such as
the one shown in FIG. 4, such as an adhesive label, which can then
be adhered to the secondary packaging. The label can be small or
large. The label can be used as part of the means to seal the
secondary packaging, or the label can cover a portion of the
outside surface area of the secondary packaging which is not near
any of the sealing means, that is flaps, tear strips, insert
pieces, seams, etc. of the secondary packaging. Although printing
on labels first has the drawback that it requires a second step of
adhering the labels to the packaging, this method is presently
preferred, because not all the contact lenses ordered will be
produced for doctors or patients who will want to have the
customized graphics added to the packaging. The preferred method of
printing out labels will be described in more detail below.
[0030] Alternatively, the customized graphics can be printed
directly onto the secondary packaging. The secondary packaging may
be assembled or disassembled at the time of printing with or
without the primary packages within. For example, if the secondary
packaging is a carton, the customized graphics may be printed on
the carton as a flat carton blank or as an assembled carton which
is empty. A support for an assembled empty carton which can be used
during printing on the carton is disclosed in Duis et al, "METHOD
AND SUPPORT FOR CARTON", U.S. Ser. No. 09/217,879, filed Dec. 21,
1998 (VTN-442) incorporated herein by reference. Alternatively, the
carton may be printed on directly after the contact lens primary
packages are inserted into the carton, by laser or ink jet
printing. Alternatively, a label having a blank area may be added
to the carton and then the customized graphics may be added to the
label. If the secondary packaging is not a carton the preferred
printing techniques for printing on the secondary packaging can be
adapted to the secondary packaging materials used.
[0031] Alternatively, the customized graphics can be printed onto
an insert which can be inserted into the secondary packaging for
example in a manufacturing line before the secondary packaging is
sealed.
[0032] Printing on the packaging, e.g. primary packaging, secondary
packaging, and/or package insert can be by any printing method e.g.
by thermal, laser, electrophotographic, ink jet, and pad printing.
Some methods are better suited for certain types of packaging
materials, which are known to a person of ordinary skill in the
art. The preferred method for printing on a label will be described
below.
[0033] For each embodiment, the method of printing the customized
graphics begins with an order from a doctor for prescription
contact lenses. The orders are received according to methods known
in the prior art, e.g. mail, telephone, internet, fax, except that
the order methods are modified so that the doctors/patients have
the ability to indicate what customized graphics they would like to
have on the packaging and optionally where on the packaging the
customized graphics are to be placed. Preferably, there will be a
large collection of pictures, photographs, and messages to select
from, and each item in the collection will be coded and stored in
computer memory, which will be accessible to the printing
apparatus. In addition, preferably, the doctors can specify
pictures, photographs or messages outside of the collection. For
example, when Dr. Jones calls in his order, he can specify which
cartons, if any, to print the photograph of himself which he
previously provided to the manufacturer, and is stored in the
computer memory which is accessible to the printing apparatus.
Depending upon what packaging is to receive the customized
graphics, that is, primary packaging, secondary packaging, or
inserts and if the customized graphics will be added to the
packaging in-line or off-line will determine how the order
information will be processed. If the customized graphics are to be
added to the primary packaging, then the order information will
preferably be sent to a manufacturing line which has a printer for
the lidstock or labels for the lidstock so that the customized
graphics can be added to the primary packaging prior to placing the
primary packaging in secondary packaging. If the customized
graphics are to be added to the secondary packaging, the
information can be sent to a contact lens manufacturing line which
will either print directly onto the secondary packaging or will
print onto a label for the secondary packaging either prior to or
after putting the primary packages of contact lenses into the
secondary packaging. The packaging which has been modified
preferably will be marked with an identification means, preferably
a machine readable identification means identifying to whom the
order should be sent so that it can be tracked and sent to the
correct doctor or patient. Alternatively, often packaging has a
unique machine-readable code (e.g. product identification means)
present on its exterior which is used to identify the product and
other information, such as, lot number, stock keeping unit (SKU),
and expiration date. This machine-readable code can have additional
information assigned to it (which is preferably stored in a
database) identifying that the package has received customized
graphics and to whom the product should be routed. Alternatively or
additionally, the exterior of the packaging can be marked with a
human-visible indicator signifying that the package has received
customized graphics which may be tracked by an operator or will
assist a quality check by an operator before shipping an order.
[0034] Presently, the preferred method is to manufacture the
contact lenses, place the contact lenses in primary packaging,
place multiple primary packages of contact lenses in secondary
packaging and sterilize the lenses by the customary methods
described in the prior art, and then to add the customized graphics
to the secondary packaging using a label printed off-line, and
preferably added off-line. Preferably, the order information for
the customized graphics is sent to a customized graphics printing
system which is separate from the contact lens manufacturing line.
The customized graphics printing system will print out labels which
will cover at least a portion of the outside surfaces of the
secondary packagings, e.g. cartons. Preferably, the doctor's orders
will be picked from stock in the customary method of assembling the
ordered contact lenses in their customary secondary packaging. The
labels produced on the customized graphics printing system will
then be matched up with the secondary packaging for each doctor's
order and then the labels will be adhered to the secondary
packaging either in an automated method or manually. After the
labels are adhered to the secondary packaging in accordance with
the doctor's order, the order will be shipped directly to the
doctor or patient.
[0035] In an alternative method, the customized graphics can be
added in-line, that is, in the manufacturing line in which the
contact lenses are produced, and placed in the primary packaging
and preferably also placed in the secondary packaging. In the
in-line mode, the order information will be provided to the
manufacturing line which is producing the ordered contact lenses
and the customized graphics will be generated right in the
manufacturing line, and added to the packaging in-line. If the
customized graphics are to be added to the primary package, at
about the time the ordered contact lenses are placed in each of its
primary packaging the customized graphics will be added to, for
example, the lidstock, and then the lidstock will be heat-sealed to
the bowl. If the customized graphics are to be added to the
secondary packaging, the carton preferably will be printed on in
the manufacturing line prior to placing the primary packagings into
the carton and prior to sealing the carton. The printing can be
accomplished by any of the methods listed above. The exterior of
the packaging, for example the secondary packaging, will preferably
have an identification means, preferably a machine-readable code,
to which the information in connection with the customized graphics
will be stored for delivery to the correct recipient of the contact
lenses.
[0036] In the preferred method, the graphics will be added
off-line, and there will be one or more computerized databases
which will track the doctors names and the selected customized
graphics. As the orders for prescription products come in, as
described above, and assembled in a database the order information
will be searched for a request for customized graphics or for a
doctor's name who has requested customized graphics on all of
his/her packaging. (Alternatively, the order information will be
searched for the patient's name that has requested the customized
graphics). When one or more orders are found which have requested
customized graphics, the customized graphics information will be
sent to a customized graphics printing system. In the preferred
mode labels having customized graphics will be printed by the
customized graphics printing system. Afterwards, the labels will be
matched up with the correct packaging, preferably cartons
containing the ordered contact lenses. The preferred method of
assembling or picking the ordered products is according to the
method and by using the apparatus and method disclosed in Duncan et
al, "Apparatus and Method for Automated Warehousing and Filling
Orders for Multi-Item Inventories", U.S. Ser. No.______, filed
concurrently herewith, (VTN-453), incorporated herein by reference.
The picked (assembled) order will be deferred to the off-line
customized graphics printing system for the application of printed
labels having the customized graphics to the cartons to receive the
labels in accordance with the orders.
[0037] The preferred off-line method for producing labels having
customized graphics comprises a printing step, and one or more
quality-checking steps. More preferably the method additionally
comprises a varnishing step. Most preferably the method
additionally comprises one or more cutting steps. These and other
steps will be described in relationship to the preferred system for
printing out labels having customized graphics as shown in FIG.
5.
[0038] FIG. 5 shows the presently preferred customized graphics
printing system 500 comprising a printer 502, a quality check
station 505, a varnish application apparatus 508, a cutting
apparatus 509, a label applicator 513, and preferably shop floor
controller 512. The shop floor controller 512 is a computer, or the
like, tracks the labels within the printing system 500. The shop
floor controller comprises memory, programs, processor, databases,
and the ability to receive information, e.g., from parts of the
printing system 500, and output information, and instructions,
e.g., which effect the function of parts of the printing system.
The operation of the shop floor controller 512 will be described
below.
[0039] Preferably orders for contact lenses and customized graphics
are received by a separate order processing system and communicated
to the shop floor controller 512, preferably from a central
customer order machine server (not shown). Customer orders can be
received by phone, mail, internet, facsimile, or by any method.
Some order taking procedures are disclosed in U.S. Pat. No.
4,958,280, incorporated herein by reference, others are known in
the art. Preferably, only the orders to receive customized graphics
are communicated to shop floor controller 512. Order information
includes, e.g. an order number, date of order, the person ordering,
products ordered, the customized graphics to be printed on the
cartons, and shipping address. In the preferred system 500, the
shop floor controller 512 sorts the information in the orders for
the labels that are to be printed onto the web, and stores this
information in a database. FIG. 6 shows a database 60 which can be
used to store the sorted order information. FIG. 6 is only
exemplary and more or fewer fields can be used to track the labels
in the printing system 500 which would be apparent to a person of
skill in the art. The database 60 includes fields for the order
information such as the order number 61 (each order has an order
number), and product SKU 62 identifying the type of product
ordered, and the customized graphics 63, 64 which was specified by
the doctor and/or patient for the product. Graphics field 63
specifies, e.g., background art. Graphics field 64 specifies, e.g.,
a message. More or fewer fields can be provided as desired. Other
fields, e.g., the SKU field can indicate additional non-customized
graphics to be printed onto the label. One or more of the fields in
database 60 may be keyed to additional databases which may provide
additional information when needed, e.g. the order number may be
keyed to a database having the doctor's name and address, and/or
the identifying numbers in the graphics field are keyed to
databases which indicate what graphics will be printed by the
printer 502.
[0040] Preferably labels from the same order are printed adjacent
to one another, and labels having similar graphics (e.g. the same
background picture) are printed close to one another on the web,
and a label identification means is assigned to each label. The
sorted label information is communicated to the control unit 501
for the printer 502. A spool 550 of a web of label material
preferably 32 cm wide is fed into a digital printer 502. The label
material preferably consists of a polyvinylchloride coated paper
top layer with an adhesive coated back, and a removable peel layer
as described in reference to FIG. 4. An example of a commercially
available web is a white-pigmented PVC with matte imprintable top
coat on paper having an adhesive layer, such as Datacal PLV-400-FW
Opaque MT/C-354 V-29 S50K-8, available from Flexicon Co. In the
preferred mode the web is blank and not pre-cut or scored; however,
in alternative embodiments the web could be pre-cut, scored, and/or
have non-customized graphics pre-printed on the web. For example,
the labels could be printed individually instead of on a web,
and/or the labels could also have the brand information pre-printed
on them. At present, there are preferably at least 5,000 labels
printed onto the web on each spool. After all the labels to be
printed onto a first web have been printed onto the first web, the
first spool 550 is removed from the printer 502 and replaced with a
second spool 550 having a blank second web.
[0041] The digital printer 502 preferably has the ability to vary
100% of the text and graphics for each label. The preferred printer
is available from Xeikon or Indigo. The control unit 501 for the
printer 502 controls the printing of the labels and instructs the
printer 502, which customized graphics, and contact lens
information, if any, to print on the labels as instructed by the
shop floor controller 512. Each label also preferably has some
label identification means, printed onto the label or on the web
next to the label so that the label can be tracked. Unique
information associated with the label identification means 65 is
stored in database 60 in the shop floor controller 512 preferably
with the location of each label on the web (preferably in fields
67, 68, 66 for row column and spool number, respectively), the
customized graphics 63, 64 specified by the doctor or patient, and
the product SKU 62 to receive the label. After the web moves
through the printer 502 it is accumulated in an accumulator 504
before passing through a quality check station 505 which preferably
uses visual inspection equipment 520, such as a spectrophotometer
or densitometer to check the color density and registration of the
toners, pigments or dyes. Densitometers and spectrophotometers
useful for this application are available from Gretag Macbeth, such
as Spectro Eye Spectrophotometer D200-11 Process Densitometer, and
D19C Densitometer, and available from X-Rite, Inc., such as SP99
Multi-Angle Spectrophotometer, and 408 Color Reflection
Densitometer. Presently, the densitometer is hand-held; however, a
fixed densitometer may be used in the method of this invention.
Additionally, an operator can perform a subjective evaluation of
the labels.
[0042] Presently, the visual inspection equipment 520 may
continuously check the quality of the graphics and provide feedback
to the control unit 501 which will cause the printer to
automatically make adjustments, or will notify an operator if the
printer cannot self-correct a printing problem. If the print
quality is below a certain level, the labels in that area of the
web will be rejected, which will be noted in the label control
system 503 (computer comprising processing instructions and
memory), and communicated to the shop floor controller 512
(computer comprising processing instructions and memory) which will
schedule the rejected labels for reprinting. The rejection will be
noted in field 69 of the database 60,and the shop floor controller
512 will instruct that the rejected label be reprinted. This can be
accomplished by moving the fields 61, 62, 63, 64 for any rejected
labels into a later record in the database with other incoming
order information, while maintaining the rejected label information
in the other fields for tracking purposes.
[0043] Preferably, an operator at the quality check station 505
will do a visual inspection of the labels on the web at set
intervals, e.g. every 15 minutes. At that time an operator will
scan the label identification means on the web with a handheld
scanner 519 which will input at least one label identification
means in the area of the web which is being inspected into a label
control system 503. The handheld scanner 519 preferably is a bar
code scanner. If there is a problem with the labels, the operator
will communicate through the handheld scanner 519, via a keypad or
the like, to the label control system 503 that the labels have
failed inspection, and all the labels printed since the last
operator inspection are to rejected. The rejected labels since the
last inspection will be determined by the label control system 503,
and communicated to the shop floor controller 512. The rejection of
the labels will be noted in database 60 in field 69 and eventually
those labels will be reprinted.
[0044] After the quality of the print is checked the web is rewound
in a rewinder 506. The core of each spool 550 has an identification
means, preferably a machine readable code, such as a bar code or
the like, so that the shop floor controller 512 and label control
system 503 can track each spool 550, and associate in the database
60 the identification means of the labels with the spool 550 on
which the labels have been printed. (The label control system 503,
preferably has a database similar to database 60). If individual
labels on the spool do not pass inspection, or if the whole spool
does not pass inspection, the control system 512 will instruct the
printer to reprint the labels and update the database 60 and also
communicates to the label control system 503 the new location (row,
column and spool) of the reprinted labels. Preferably if any of the
labels for a single order do not pass inspection, all the labels in
an order will be reprinted on a new spool to keep all the labels
for the same order together.
[0045] Next, the web on the spool will preferably be unwound on
unwinder 507, and fed into a varnish station 508 in which the web,
particularly the labels on the web, will receive a UV radiation
cured varnish to improve their looks, and increase the labels'
abrasion resistance. An example of a suitable varnish is INXCURE UV
FLEXO P/I COATING which can be applied by, for example, a Belmark
varnish applicator, which comprises anilox rollers. Preferably the
web is inspected after the application of the varnish to be sure
that the varnish was correctly applied and to check for any other
flaws or errors. The inspection can be by an operator or by visual
inspection equipment (not shown) similar to the apparatus and
method described above. The inspector will preferably use a second
handheld scanner 519 to input the identification means of the
labels checked, and again individual labels or the entire web may
be discarded if there is a problem with the varnish applicator and
labels do not pass inspection. If the web is to be discarded the
label control system 503 will note the identification means of the
spool, and communicate this information to the shop floor
controller 512, which will update the database 60, particularly
field 69, and which will instruct the printer 502 to reprint all
the labels on the spool. If only certain labels are to be
discarded, the label control system 503 will note the label
identification means of the labels that did not pass inspection,
and will communicate this information to the shop floor controller
512 which will update the database 60 and which will instruct the
printer 502 to reprint the labels that are to be discarded.
Preferably all the labels in an order will be reprinted together on
a single spool.
[0046] After inspection, the web is fed into a die cutter 509 which
cuts the labels through the top layer of the web, and in a next
step the top layer of the web around the labels is removed from the
web, leaving the labels on the peel layer. In the preferred
embodiment two separate apparatuses manufactured by Preco perform
the just-described steps. In the preferred embodiment, multiple,
e.g. three columns of labels are printed on the web. After cutting
the labels, the web is cut widthwise into smaller reels 551, e.g.
three reels, in a slitting machine 510. The reels are tracked by a
machine-readable code on the core of each reel. Prior to slitting
the web, the label control system 503 updates its database by
assigning the labels in each column on the spool to one of three
reels, which is noted in field 70, when the reels and spool are
mounted upon the slitting machine. The labels are preferably
printed on the web, so that labels for products in the same order
are printed adjacent to one another in the same column. As shown in
FIG. 6, the three products for order number 10,175 are printed in
column 1 of spool 2.
[0047] Presently, labels are only printed for products which are in
inventory; therefore, any reel 551 can be selected by an operator
and put on the label applicator 513. When the machine readable code
for the selected reel is inputted into the label control system
503, preferably via a reader (not shown) located on the label
applicator 513, the products onto which labels are to be adhered
are pulled from inventory and sent to the customized graphics
printing system 500. In an alternative embodiment, each reel 551
can be set aside until all the cartons that are to receive the
customized labels on that reel have been picked from inventory. In
either embodiment, the orders for which the labels are ready for
placement on the products are communicated from the shop floor
controller 512 to order picking and/or assembly equipment (not
shown) which picks the cartons from inventory. Preferably, the
cartons which are to receive the labels are transported to the
label applicator 513 on a conveyor 514 (cutaway section shown),
preferably the cartons are in the same sequence as the labels for
the cartons on the reel 551. Alternatively, the cartons could be
transported in assembled orders in a container or belt section (not
shown) of conveyor belt 514. Each belt section can have a
machine-readable code tied to the order which is within the belt
section. The machine-readable code of the belt section and the
related order information could be communicated to the shop floor
system 512 from the equipment which assembled the orders. In any
embodiment, preferably the orders are conveyed to the system 500 in
the same sequence that the customized labels for the orders are
present on a reel, and/or preferably the product cartons within an
order are conveyed to the system 500 in the same sequence that the
labels for the orders are present on the reel. Preferably, the
cartons are conveyed to the label applicator on a one carton-wide
conveyor 514 in exactly the sequence of the usable labels on the
reel.
[0048] The cartons are conveyed to the label applicator 513. A
product handler e.g. a robotic arm (not shown) may be used to pick
product off the conveyor and place the product into the label
applicator 513. Useful labelling equipment is commercially
available. As each product receives a label it is preferably pushed
or placed on a second conveyor 517 which transports the products to
a final verification, packaging and shipping area (not shown). The
products are preferably maintained in the same sequence, preferably
with spaces between individual orders on conveyor 517.
[0049] Preferably, the label applicator 513 will only apply a label
on a carton after verifying that the proper carton is present by
reading the identification means on the conveyor section (if
applicable) via a reader (not shown), and/or by reading the
identification means on the carton via a reader (not shown), and/or
by reading the label identification means via a reader (not shown).
The label applicator 513 will automatically skip the labels on the
reel, which are to be discarded. (The shop floor control system 512
provides the tracking information on the labels as recorded in
database 60 to the label applicator 513.) The label applicator 513
also preferably comprises an inspection mechanism (not shown) which
makes sure each label is in the proper position and without
wrinkles prior to allowing a carton to be conveyed to shipping. If
the inspection mechanism, such as a vision system, or an operator
does not pass a labeled product, preferably the cartons which do
not pass inspection are discarded and the method will be repeated
from the beginning for those cartons, and the rest of the cartons
in a single order will be set aside. If there is an error in the
applicator 513 that requires an operator's attention, the operator
may use the handheld scanner 519 to communicate to the label
control system 503 that certain labels should be discarded, which
will be noted by database 60 and the shop floor controller 512.
This step can be done at any point in the method of printing or
otherwise producing the labeled product.
[0050] The label applicator 513 preferably continues the verifying,
labeling, and inspection steps until all the labels on the reel
have been put on cartons. When the reel has no more labels to
apply, a signal to an operator will indicate that the reel 551
should be changed, and either the operator can place whichever reel
he/she wants onto the label applicator 513, or the shop floor
controller 512 will communicate to the operator the next reel 551
to put on the label applicator 513, and the process of applying the
labels will continue.
[0051] Before and/or after the application of the customized
graphics, the packaging may have no human-readable identification
of the prescription of the product and may only comprise a
machine-readable identification means which is used to track the
product through manufacturing and shipping. The customized graphics
preferably will identify who the product is for, and may not
indicate any prescription information. This is particularly
beneficial to prevent the product from being provided to a person
who does not have a proper prescription for the product.
[0052] While there has been shown and described what are considered
to be preferred embodiments of the invention, it will, of course,
be understood that various modifications and changes in form or
detail could readily be made without departing from the spirit of
the invention. It is, therefore, intended that the invention be not
limited to the exact form and detail herein shown and described,
nor to anything less than the whole of the invention herein
disclosed as hereinafter claimed.
* * * * *