Are you prepared to move quickly to meet the new standards set to be released by the FDA by the end of this year? The Food Safety Modernization Act of 2011 gives the FDA broad powers to closely inspect food manufacturers and enforce strict traceability standards across the industry. Legally mandated facility inspections will start in 2016.
Here is what we know:
FSMA Rules & Guidance For Industry
A comprehensive listing of the draft proposals that are likely to go into effect as enforceable regulations.
GS1: Product Tracing, Critical Tracking Events and Key Data Elements
Moving toward a single global standard for implementing traceability measures in the food and beverage industry.
Product Coding Technologies
Small Character Inkjet
Case Coding Technologies
High Resolution Inkjet
Print and Apply Labeling
Large Character Inkjet (Dot Matrix)
Pallet Coding Technologies
Print & Apply Labeling
If you haven’t had a top-to-bottom review of your coding and labeling operations within the past 5 to 10 years, you are probably overdue for a comprehensive product identification site audit. Technological advancements have allowed for manufacturers to achieve greater efficiencies and accuracy with their product coding efforts for all levels of packaging – from primary products all the way to pallet level labeling.
Diagraph can take the guess work out of coding and labeling operational best practices by offering free comprehensive site audits. We make a series of recommendations that span anywhere from making modifications to current equipment or practices for enhanced productivity to the complete retooling of your product identification operation to help you achieve your production and packaging compliance goals.
Our site audits include a close review of the following key areas:
After reviewing these key areas and other aspects of your packaging compliance requirements, we provide a site audit report with simple recommendations that you can implement immediately as well as bigger picture recommendations that can be implemented overtime with planning and support. At Diagraph, our goal is to make it easy for our customers to achieve the perfect mark on their products. Regular site audits and account reviews are just one of the ways we work in partnership with our customers.
Call us today at 800.722.1125 to learn more about how Diagraph partners with manufacturers to achieve product identification and packaging compliance success.
Fast-paced lifestyles of the working class and a growing number of Millennials demanding on-the-go options are two contributing factors to the rise in the ready-to-eat (RTE) prepared foods market with a projected CAGR of 7.2% between 2016-2026. (Source: Ready-to-Eat Food Market: Meat/Poultry Segment Expected to Dominate Market from 2016 to 2026: Global Industry Analysis and Opportunity Assessment, 2016-2026)
What exactly classifies a product as RTE? According to the Food and Drug Administration (FDA), a ready-to-eat product is defined as “animal or plant derived food that is cooked, frozen, washed, cooked for hot holding, cooled, and processed to be consumed directly or after heating.”
Packaging for RTE food products can come in many forms or in a variety of materials including aluminum foils, extruded polyethylene, low-density polyethylene (LDPE) and cellophane. These types of materials offer versatility for keeping food shelf-stable, while utilizing less shelf space and materials than traditional tin cans and many allow for cooking food directly within the package for eating or serving. A common RTE package used for microwaveable soups, sauces, rice and pasta dishes are stand-up pouches. This flexible packaging format is also commonly seen in prepared baby foods, juices, yogurts and wet pet foods.
These newly designed packages raise questions on how to properly make required expiration and identification marks. Consider the following factors:
Packaging substrate – Most common RTE meal packaging is made up of non-porous plastics or foils, meaning your mark either requires ink or ribbon that will adhere to non-porous surfaces for a permanent mark solution
Branding – Consumers value freshness, portion control, and perceived health benefits of these RTE products meaning new creative packaging innovations are necessary to stand out on the shelves. This requires finesse from the manufacturer or packager in strategically placing freshness dates in locations on the product that are easily visible by consumers and maintain permanency without compromising the integrity of the brand packaging
Integration – If your product is packaged via a vertical or horizontal form fill and seal machine, consider marking and coding printers that will most easily integrate into that process to still achieve demanding throughput goals
If you’re a food manufacturer focused on the ready-to-eat meal or snack market, it is critical to have the right partner in place to assist with marking and coding solutions that won’t disrupt your operation. According to the study Ready-to-Eat Food Market, the North American RTE market is forecasted to be valued at $78.73 billion. (Source: Ready-to-Eat Food Market: Meat/Poultry Segment Expected to Dominate Market from 2016 to 2026: Global Industry Analysis and Opportunity Assessment, 2016-2026)
Our experts are ready to speak with you about how our thermal transfer overprinters or continuous inkjet systems can meet your product identification needs.
The Container You Choose for Your Brew Determines Which Coding Technology You Should Choose
An excerpt from 2016 Comprehensive Guide to Date and Batch Coding in the Craft Brewing Industry
Different types of technology are needed for printing on your primary (bottle or can) package and on your secondary (outer box) package. Continuous ink jet (CIJ) and laser are the most common options for printing date codes, batch codes, other text, graphics, barcodes, QR codes and other codes onto primary beverage packages.
When selecting a coding system for your primary packaging, the first step is to consider what type of material you will be printing on. Keeping in mind that you can reasonably expect the printer to last five to seven years, what types of packages are you using now and do you plan to use in the years ahead? Bottles can be coded with either laser or CIJ systems. Cans are coded with CIJ technology. This means that a craft brewer who wants to be able to code on both cans and bottles will need a CIJ system.
The next consideration that should factor into your coding technology decision is production volume. Download our free guide to view cost comparisons based on the number of bottles and/or cans you fill per day.
2016 Comprehensive Guide to Date and Batch Coding in the Craft Brewing Industry
As a leading provider of marking and coding technology, Diagraph works with breweries of all sizes across the country to fulfill product traceability needs that can easily scale up for future capacity and complexity. Diagraph manufactures batch coding and date coding technologies that span the entire packaging line -- from primary product to secondary packaging all the way to pallet labeling.
How do you Print on a Sachet or Stickpack?
By Steve Dods, Automated Labeling Products (ALP) & Thermal Transfer Overprinter (TTO) Products Manager
Sachets are packets or sealed pouches that contain liquids, gels, or powders and typically sealed on four (4) sides. Stickpacks are tube-like packaging that is sealed on two ends with a continuous seam side. These convenient packaging methods are highly utilized in the food and beverage additive markets, but can be seen in pharmaceutical as well as cosmetic industries.
This packaging type requires a specialized system to form the packaging receptacle, fill the product into the packet, and seal the ends to secure the product for transport. These systems are known as FFS, Form, Fill, and Seal machines, and they come in two different varieties. Once is Vertical, or VFFS, and the other is Horizontal, or HFFS. Vertical uses gravity to aide in the filling process, where horizontal is generally high speed by using mechanical methods for filling.
Since sachets and stick packs can be sold individually, there can be the need to print information about expiration date and lot code onto the individual products. Since it is far less accurate to accomplish this task once they are filled, due to irregularities in shape and placement control, it is done "upstream". Upstream of the fill process is where the film or web is unwound from a large roll. This is the best location to mark and code the product - before it is individualized in the process. There are many ways to accomplish this type of date / lot / id coding, but there is one that stands out amongst the rest.
In marking the products in the web matrix, there are several "lanes" of product on the master web. That means higher fill rates by handling multiple products in each indexing move through the process. A typical number of adjacent products is 5 or 6, but some are as few as 4 or as high as 12. In rare instances, lanes numbers exceeding 12 have been realized. Due to these high number of prints required at each indexing interval, traditional methods of marking are usually ruled out.
Of the possible marking methods, there are a few that have been used in practice. One is to brute force out the marking process by using multiple ink jet print heads. This is somewhat difficult to manage, as there is a requirement for non-porous ink to mark the web, which tends to have issues with the short decap time and fast dry times that can clog or require higher maintenance. Most objections from OEM FFS manufacturers and end users is the mess and chemicals in close proximity to dispensing foods and powders.
Another method is to use TTO (Thermal Transfer Overprinting) to traverse across the web to mark an indelible print using a clean ribbon method. This works, but the throughput rates suffer due to the time it takes to sweep laterally across the web each time. On the same idea, there are traversing ink jet solutions as well. They again suffer from the points above, and additionally add the time component for the sweep across the web.
The best method that eliminates the weaknesses of the aforementioned methods is the multi-lane intermittent (MLi) TTO system. The MLi incorporates a plurality of print heads to match the number of lanes requiring print. It utilizes one ribbon, to avoid multiple consumables running out at various, unsynchronized times. It is able to print very quickly, since each head can print simultaneously, each covering an area up 100 mm (across the web) x 52 mm (in the direction of web movement). Systems like these may have a slightly higher upfront price, but more than make up for it in much higher uptime and ease of use. Maintenance is fair less, and it requires little skill to perform daily operation functions, since loading a ribbon is straight forward.
Diagraph, An ITW Company is a leading manufacturer and distributor of marking, coding and labeling systems and supplies, and has been in the product identification industry for over 120 years. Diagraph’s products include all-electric printer applicator labeling systems, LINX continuous ink jet and laser coders, large character ink jet printing systems and thermal transfer overprinting systems. For more information, call 800-722-1125, send emails to firstname.lastname@example.org or visit diagraph.com.
While the utmost care is taken to ensure that meat for human consumption is processed in hygienic environments, the law requires that meat packs are coded for traceability purposes; partly with the aim of enabling the consumer to have greater confidence in the food on their plate.
Packers need to ensure that the codes they deliver onto meat products can give customers and those further along the supply chain all the information they need to trace where it has come from effectively. With the meat and poultry industry ranking as the largest segment in U.S. agriculture, total industry production accounted for more than 92.9 billion pounds of meat and poultry product in 2012. The need to track meat products all the way through the supply chain is crucial to the health of the industry as a whole.
Coding and marking for meat packaging
Coding machines have the ability to deliver traceability information such as the source of the meat, or where it was processed, on products and their packaging, helping to ensure that consumers have peace of mind when they purchase meat (or other food).
Meat processors have various ways in which they can deliver traceability and peace of mind through coding. Whether these are print and apply barcode labels, accomplished using high-resolution continuous inkjet technology or other measures, packers need to have confidence that their coding and marking printers can deliver the right information on products that will stay put – whatever the substrate.
Human error – for example selecting the wrong message to be printed, or entering a code incorrectly - can also potentially cause production delays and product scrappage. However coding technology can help to alleviate this through advances such as remote control or monitoring of printers, or easy-to-use image-based operating software. This means packers have less to worry about, such as costly downtime in an industry that can little afford it.
Why do we need traceability codes?
Traceability requirements are partly designed to help consumers have greater confidence in where their food has come from and improve the accountability of manufacturers; as such legislation has set out a number of laws to deliver just this.
The FDA Food Safety Modernization Act (FSMA) of 2011 is the most robust regulatory act passed in the United States in nearly a century. The food and beverage industry anticipates the release of well-defined FSMA rules by the end of 2015 and the oncoming enforcement of those rules by the FDA by the end of 2016. The timeline outlined above is mandated by a court order. The industry can reliably expect legally mandated inspections of food facilities to begin in 2016.
This modern emphasis on traceability is not just helpful information for consumers, who can tell quickly the origin of their food, but also ensures that any product recalls are limited to the specific items affected – minimizing disruption to a meat processing business. Knowing which affected products were included in a particular lot over a period of time will help prevent manufacturers from having to recall everything – leading to a more accurate and controlled recall process when issues arise and significant cost savings.
Traceability can also help to support the integrity of different types of meat manufactured and processed, for example halal, kosher or organic meat; all of which should be processed under strict guidelines.
If you want to learn more about the best coding and marking solutions for the meat processing industry, download our white paper CHOOSING THE BEST MEAT PROCESSING CODING SOLUTION.
Common GS1 Barcodes Pictured Above. The following can be printed by Print and Apply Labeling and most High-Resolution Inkjet Technologies:
Barcodes: UPC-A, EAN-13, UPC-E, EAN-8, GS1 DataMatrix, GS1 QR Code, GS1-128, ITF-14
GTIN Types: GTIN-8, GTIN-12, GTIN-13, GTIN-14
Many major retailers and distribution centers require manufacturers to display important information on all four sides of cartons and cases that are intended for backroom storage purposes. This offers retailers ultimate flexibility for their inventory management programs.
The following information is important to effectively manage inventory:
Having this information visible on your box is usually not enough. Manufacturers need to ensure that this important information is large enough and clear enough to read from a distance.
4-Side Print Solutions
Unfortunately, there are not any one-size-fits-all solutions to accomplish four-sided printing on cartons. Flexographic and lithographic pre-printed boxes are not practical for the important variable information needed with every shipment (i.e., best by date and lot/batch code). Manufacturers can turn to a combination of pre-printed information and print-on-demand information if flexographic elements are required. However, complete print-on-demand solutions offer manufacturers the greatest flexibility in terms of cost and supplies.
Print and Apply Labeling 4-Side Print Solutions
Because manufacturers have more options when choosing to use a labeling solution for their four-sided print requirements, the best solution for your particular operation depends largely on the speed of your line and your product throughput. The most efficient option in terms of the equipment required would be to opt for two opposing E-FASA (swing arm) print and apply labeling machines. One machine would apply the label to the front and the side of the box while the other would apply to the opposite side and the rear panel. This solution does not require a bump turn material handling mechanism.
The Diagraph PA/6000 with E-FASA tamp applicator module offers the greatest flexibility for manufacturers. The all-electric design frees the labeler from shop air, allowing it to be placed anywhere on the packaging line. Additionally, the servo motor and smart sensing technology unique to the PA/6000 system ensure that labels are precisely placed on time, every time.
If retailers and distribution centers require flexographic and lithographic printed barcodes, you can more easily manage pre-printed label stock than a large pre-printed box inventory. Utilize flexographic printed labels for all information that will remain the same and utilize the labeler’s printing capability to print the important variable information on demand. With that being stated, it is important to point out that printing barcodes using a wax-resin ribbon and a thermal print head onto consistent label stock is a highly reliable print method. The recommendation to get pre-printed label stock depends entirely on retailer requirements, but is not necessary if you want the print and apply labeler to handle your entire print message – including the barcodes.
Large Character Inkjet 4-Side Print Solutions
Many manufacturers can get away with only displaying information on one or two sides of a case. To accomplish print on two opposing sides, manufacturers need inkjet printers installed on opposite sides of the packaging line. At Diagraph, our high resolution large character inkjet system – Diagraph IJ4000 – can drive printheads on opposing sides of a single line from a single system. The unique centralized ink delivery system in the Diagraph IJ4000 allows floor operators to monitor and change fluids from a single location rather than having to monitor each individual print head.
Additional material handling is required when setting up your packaging line for four-sided printing. A “bump turn” material handling method is required to rotate the box 90° to present the remaining two panels for printing. Two additional opposing printheads need to be installed further down the line, positioned after the bump turn mechanism, to print on the remaining panels. Four-sided box printing can easily be accomplished using the Diagraph IJ4000 once the bump turn mechanism is in place on the packaging line. A single IJ4000 system can drive all four required printheads from a single system, allowing up to a 2” print height for the printed information.
Printing variable information using a Diagraph IJ384e printhead offering a maximum of 2” characters satisfies size requirements for most retailers. If larger characters or a larger print area is desired, manufacturers can opt for the Diagraph IJ768e printhead, which offers up to 4” of print height. A single Diagraph IJ4000 system can drive two IJ768e printheads, which means two systems would be required for a four-sided printing application. Many of our customers opt for the IJ768e 4” printhead to take advantage of the larger print area and future-proof for expanding retailer requirements.
The Diagraph IJ4000 system prints high resolution text, graphics and machine readable barcodes, including GTIN, ITF and GS1 varieties.
Additional Quality Assurance Measures
Both high resolution inkjet and print and apply labeling technologies can print machine readable barcodes with high quality resolution. Many of our customers install a fixed mount barcode imager to test the barcode quality. This information is sent to a PLC which reads the good or bad output from the barcode imager and stops the conveyor when a barcode gives a bad result. This extra quality measure ensures that only readable barcodes reach retailers.
Material Handling Solutions Provided by Diagraph
At Diagraph, we have customers large and small who have varying degrees of internal resources and packaging line expertise. We offer project management services for manufacturers who choose a Diagraph solution and need to outsource the material handling changes to their lines. Our dedicated engineers work closely with manufacturers to design a material handling solution that will meet their unique application need.
Still have questions about printing variable information on all four sides of a box? Contact us today to learn more about your options: Call 1-800-722-1125 or email email@example.com.