This article was originally published on 4-18-2023 and updated on 6-30-2025.
Companies across many industries are increasingly utilizing RFID-enabled labels and tags to improve efficiency with real-time data capture and automation. RFID technology plays a critical role in improving visibility and control across supply chains from inventory tracking in retail to pharmaceutical traceability.
Offline vs. Inline RFID Inlay Insertion Systems
Many RFID label production workflows still rely on offline systems, where printing, RFID inlay insertion, and finishing occur in separate stages. While this approach can offer flexibility for certain applications, it often slows down throughput and increases material handling. To keep up with high-volume demand, more manufacturers are adopting inline RFID insertion systems, which combine all production steps into a single, continuous process, maximizing efficiency and scalability.
Single-pass RFID insertion addresses these challenges by combining printing, inlay insertion, and finishing into one streamlined operation. This approach reduces labor costs, and streamlines operations, making it a smart investment for label converters and packaging manufacturers looking to stay competitive in a data-driven market.
Understanding Single-Pass RFID Insertion
Single-pass RFID insertion is a manufacturing method that embeds RFID inlays into labels or tags during a continuous, integrated production run. In this streamlined process, the form is printed on a flexographic press, routed to an RFID inlay insertion module, and completed with finishing, all in one pass through the machine.
Compared to traditional workflows that may require separate equipment and offline steps for inserting inlays, single-pass systems offer significant operational advantages. They reduce the number of touchpoints, speed up turnaround times, and limit opportunities for human error or material misalignment.
With high-speed insertion capabilities and precise registration controls, modern single-pass systems are ideal for large-scale production of smart labels used in retail, pharmaceuticals, logistics, and beyond. For manufacturers seeking to scale RFID integration efficiently, single-pass RFID insertion provides a more agile, cost-effective solution.
Benefits of Single-Pass RFID Insertion
Adopting single-pass RFID insertion systems offers several advantages that enhance production efficiency and product quality:
- Increased Throughput: By integrating printing, RFID inlay insertion, and finishing into a single operation, manufacturers can significantly boost production speeds, meeting high-volume demands more effectively.
- Enhanced Accuracy: Single-pass systems reduce the risk of misalignments and errors associated with multiple handling steps.
- Cost Savings: Streamlining the production process minimizes labor requirements and material waste, leading to lower operational costs.
These benefits collectively contribute to a more efficient, reliable, and cost-effective RFID label production process.
Real-World Application: A Canadian Label Producer’s Experience
A Canada-based producer of labels and printed tape sought to improve its RFID label production capabilities. By retrofitting an existing flexographic press with a single-pass RFID insertion system from Tamarack® Products, the company achieved notable improvements in its operations.
- Faster Turnaround Times: The integrated system streamlined the production process, reducing the time required to produce RFID-enabled labels.
- Reduced Human Error: Automation of RFID inlay insertion and verification minimized manual handling, decreasing the likelihood of errors.
- Enhanced Traceability: The ability to verify RFID tags in-line assured the quality of the final product, leading to customer satisfaction.
This case exemplifies how single-pass RFID insertion systems can transform label production operations, delivering tangible benefits in efficiency and quality.
Supporting Single-Pass Efficiency with Advanced RFID Equipment
To fully realize the benefits of single-pass RFID insertion, manufacturers need equipment that delivers speed, precision, and seamless integration into existing press lines. Tamarack® Products offers industry-leading RFID inlay insertion systems designed to meet these demands.
Tamarack MVW Inline RFID Inlay Insertion Equipment
- Integrated Workflow: This system enables RFID label production, including printing, inlay insertion, and finishing, on a single flexo press line.
- High-Speed, Multi-Lane Output: Runs at speeds up to 100 meters per minute (330 FPM), with up to six-lane capability for high-volume operations.
- Precision Inlay Placement: Achieves highly accurate registration of dry or wet inlays, ensuring reliability in RFID tag functionality.
- Flexible Inlay Compatibility: Supports both wet and dry inlays, allowing converters to produce a wide range of RFID-enabled products.
Learn more about Tamarack MVW Inline RFID Inlay Insertion Equipment
Single-pass RFID insertion has emerged as a powerful solution for high-efficiency label production, helping companies reduce turnaround times, cut costs, and improve product traceability. As demand for RFID-enabled products grows across sectors like retail, logistics, and healthcare, investing in inline, integrated production workflows become essential.
Tamarack® Products delivers industry-leading solutions for RFID label production with over 50 years of experience in web finishing innovation. Our MVW Inline RFID Inlay Insertion Equipment supports scalable, high-performance manufacturing with precision and speed. Contact us today to learn how single-pass RFID insertion can improve your production efficiency.
