When it comes to contract packaging, companies are increasingly looking to consolidate their code printing requirements. Using multiple devices to print onto different sized containers and different material types is costly and inefficient. Companies now need to offer a full-service solution to be relevant and competitive.
Coding requirements may differ between the primary and secondary packaging. These requirements include printing on different substrates such as plastic, cardboard and metal. Traceability requirements such as visible, permanent codes to manage product recalls may not differ, but code sizes will likely be different. You could be wasting time and money if you are using multiple printers to achieve these requirements.
Contract packagers also need to support packaging trends such as new substrates, packaging product shapes and sizes and environmental initiatives such as reducing materials. For example, packaging a product that offers single serving portions as well as the standard size portions requires a coder which can print the same information on different packaging shapes and sizes. The information must be accurate, legible and permanent to ensure traceability—it’s no use if a code can be smudged or wiped off a particular substrate.
Many contract packaging companies are introducing manufacturing techniques to cut costs and improve competitiveness. By implementing the right printing technology into your contract packaging business, you can significantly cut costs, remain competitive and offer more to your customers.
You can significantly cut costs in the following areas with a single printing solution:
Diagraph’s Linx continuous inkjet printers (CIJ), thermal inkjet, large character printers, laser coders and thermal transfer overprinters can print information such as text, dates, barcodes and logos on a wide range of porous and non-porous substrates. This enables both primary and secondary coding with easy-to-use, easy-to-maintain printers, making your contract packaging operation more efficient and cost effective.
Find out how Diagraph can help you expand your contract packing capabilities by contacting us.
No longer is it the case that snacks are packaged specifically for children’s lunch boxes. Today, the snack market is heavily geared towards adults with 94% of adults snacking at least once a day and 50% snacking 2 to 3 times a day.* Snack producers are tasked with changing traditional packaging to address a different kind of consumer.
To stay on top of fluctuating snack market trends, food companies find they need to develop new packaging such as single-serve packs, convenient on-the-go solutions, and sustainable “green” packaging. Aside from creating a trendy and appealing packaging aesthetic, snack packaging frequently requires variable codes such as “Best By” or expiration dates. With consumers growing more and more health-conscious, some code requirements include allergen information, genetic modification information, and country of origin.
Many snack food companies make use of continuous ink jet (CIJ) printing technology to meet these coding requirements. CIJ is cost- effective and has a wide range of fluids to ensure coding adhesion and legibility on both porous and non-porous packaging like cardboard, plastics, metal, glass, or flexible packaging. At a minimum, your CIJ equipment must be able to produce legible and durable date, lot, and identification codes on a variety of substrates. However, there are other key features to look for when selecting a continuous ink jet printer to keep your snack packaging operations in uptime by minimizing maintenance and human errors including:
Given the wide variety of packages and product types at snack food manufacturers, the flexibility offered by CIJ is also considered an appealing benefit. Leading systems’ printheads can be used in any orientation with 360 degree printhead positioning and many can be moved from line to line to accommodate many shapes, sizes, and levels of packaging.
Diagraph offers the Linx 8900 Series CIJ printers to help our customers produce a long lasting, quality mark on a variety of packaging materials. The 8900 Series is designed with many smart, easy-to-use features to keep your production line up and running. Live chat with one of our equipment specialists to learn more. Or, read up on the latest innovations in snack food packaging in our latest whitepaper.
2018: Innovations in Snack Food Packaging
For sachet or stick pack packaging, the Allen MLi-TE multi-lane thermal transfer printer is a top solution for coding individual expiration dates or lot codes upstream. Multiple lanes can print quickly and simultaneously, utilizing one ribbon to avoid multiple consumables running out at various, unsynchronized times. The Allen MLi’s configurable design requires only one controller and one consumable for up to 12-lanes of print, greatly simplifying packaging machine maintenance and reducing downtime.
Once your packet is coded, sachet or stick pack packaging 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: (1) Vertical (VFFS) and (2) Horizontal (HFFS). Vertical uses gravity to aide in the filling process, where horizontal is generally high speed by using mechanical methods for filling.
Today we’re doing a Q&A with an expert stick pack OEM, Viking Masek, to cover the key points to evaluate when selecting stick pack equipment to integrate with a marking and coding solution like the Allen MLi-TE.
Stick pack machines are perfect for packaging a wide variety of powder, granular, and liquid products. Powder products can be dense, fine, loose, and particulate materials. Liquids can be substances of differing viscosities including water-like fluids, gels, and pastes.
Stick packaging is very popular in many industries, especially with powdered drink mixes, liquid and powder pharmaceuticals and nutraceuticals, and granular ingredients like sugar. Contract packagers in the medical and dietary supplement industries also highly favor stick packaging equipment.
Single serve and controlled dosage packaging is very popular with todays’ consumers, spanning across many generational demographic groups. Millennials and young professionals love stick packs because they are portable, convenient, and fit unobtrusively into their busy lives. The aging population uses stick packs because they are lightweight and often feature easy-open options like tear notches, making it easier for those with limited dexterity to handle and use the product. Moms and dads are attracted to stick packs because they can easily feed their children with a single, easy to open, controlled serving size package that requires little clean up and virtually no utensils.
When it comes to selecting the proper stick packaging equipment for your unique product, there are experts available to guide you every step of the way. However, there are a few major considerations they will take into account when recommending machinery. These include:
All stick pack machines can utilize the following product fillers:
Stick pack machines can be built to accommodate different stick widths (most popular are 23 mm and 35 mm), convenient designs including pour spouts and specialty die-cut shapes, and can also feature easy-open options like tear notches and micro-perforations. Available with IQ/OQ pharma construction, stick packaging machinery is a great solution for pharmaceutical packaging.
Often stick pack clients desire to print expiration dates or lot codes on their stick packaging. There are many multi-lane printing options available, including Diagraph’s new Allen MLi-TE multi-lane thermal transfer printer.
First, do your research. This can be done via the internet, on the phone, or in person through your professional and personal networks. Attend industry trade shows and strive to see available equipment in person. When you’ve narrowed down your packaging OEM choices and are looking for more details in the form of a proposal, prepare by defining key points the equipment manufacturer will need so to provide the most accurate configuration for your specific needs. The key items that must be defined differ from powder to liquid products.
Remember that with most capital purchases, and especially when it comes to a piece of equipment you will rely on for a vital part of your production process, you often get what you pay for. Consider not only the initial purchase price of the piece of machinery, but total cost of ownership (TCO). TCO will include costs for things like training, maintenance and parts, installation, and tax implications.
Located in Southeast Wisconsin, Viking Masek manufactures, sells, and services flexible packaging machinery for food and non-food industries worldwide. Our focus on packaging innovation and investments in both technology and people makes us uniquely poised to take on unique packaging equipment projects, both large and small. Have questions about flexible packaging? Contact us today for a free Packaging Equipment Consultation.
It is estimated by the US Grocery Manufacturers Association that over half of recalls cost companies over $10M. In addition to the financial implications, recalls for defective products could be harmful to the health of your customers and ultimately damaging to your reputation. These two major factors support the necessity of product identification in the form of date codes, lot codes and batch codes to track and trace in the event of a recall.
Two common automated marking and coding solutions for food packaging are continuous inkjet and laser coding. Which solution best fits your application is dependent on a number of factors. To help you in this evaluation process, we have outlined a few consideration questions:
Continuous Inkjet Considerations
Continuous inkjet (CIJ) can mark onto virtually any substrate type, rounded or flat, ranging from plastic bags, glass jars, metal cans, paper cartons and more. Because of the variety of ink types and colors available, you can achieve a high-contrast mark on nearly any color packaging.
Laser Coding Considerations
Laser, by comparison, creates a permanent mark on most surfaces although not all packaging types will guarantee a high-contrast batch, lot or date code. The etched marks from laser will last, although on clear plastics and glass the coding may not be as easily visible as black ink from CIJ.
Continuous Inkjet & Laser Coding Considerations
Accurate batch, date and expiration codes are essential for customers and retailers alike. If your production lines perform multiple changeovers for different products each shift, this leaves room for errors. Leading CIJ and laser solutions have features for storing unique, variable messages and icon-based interfaces that can be operated without extensive training for message creation and retrieval. Reliable, accurate coding methods will keep your line running in uptime and ensure speedy recall of products in that event.
If your products have high retail value, they may be susceptible to counterfeiting. There are internal tracking and security codes that can be made on a product discreetly, that are only visible under certain circumstances by the manufacturer to verify authenticity and product origin. For CIJ, one option is security UV inks that are nearly invisible until exposed to UV light.
The low-contrast, permanent marks created from laser etching are a benefit in the case of anti-counterfeiting codes. Codes can be applied to packaging in an inconspicuous location without compromising the appeal of the packaging design.
These are only a few considerations to keep in mind when selecting between continuous inkjet and laser coding for your food or beverage packaging line. For more information on how coding ties into food safety and traceability, download our full whitepaper.
Coding for Safety & Traceability in the Food Supply Chain: A Comparison of Continuous Inkjet & Laser Coding
Marking and coding equipment should help contract packagers improve productivity. Diagraph accomplishes this by keeping equipment intervention requirements for our product identification equipment to a minimum.
Diagraph’s coding and labeling equipment runs cleaner for longer between required interventions and withstands wear and tear, increasing its useful life. This leads to greater equipment uptime and a stronger return on investment over the life of Diagraph equipment.
The number of steps required for routine interventions as well as the length of time between those interventions is minimized. Product capabilities like automatic printhead cleanings help keep inkjet coders operating with optimal print quality for longer. Examining consumable replenishment practices and centralizing ink refills or providing a quick turn label stock webbing approach makes required interventions quicker and hassle-free.
Finally, quality materials and thoughtful engineering matter when it comes to the longevity of your equipment. Diagraph’s focus on impact resistant designs – whether it be an inkjet coder or a labeler – ensures long-term product reliability.
After making sure your product coding equipment is properly matched to your application and contract packaging environment, it is essential to make sure your line operators and maintenance staff know how to properly handle and maintain your equipment.
Diagraph’s equipment is designed to have fewer touchpoints to enable hassle-free installation, training and maintenance. These easy access touchpoints minimize the amount of time required and eliminate the need to access the entire system to perform maintenance or changeovers.
Because contract packagers regularly deal with worker turnover challenges, routine training to keep workers knowledgeable and able to be good stewards of your equipment is critical. We offer refresher-level training opportunities with each scheduled service visit from a Diagraph field service engineer. In addition, in-depth training is offered on location or at the Diagraph training facility in St. Charles, Missouri.
Our most successful customers partner with us to regularly evaluate and maintain their coding and labeling equipment. We perform routine equipment assessments, provide regularly scheduled service and develop long-term equipment upgrade plans.
Equipment is kept running longer and the need for unplanned interventions is reduced by staying ahead of wear-caused failures and by properly maintaining equipment. As with all things electro-mechanical, equipment performance will eventually impact production throughputs. We help you navigate the useful life of your equipment to determine when to repair and maintain a system and when to upgrade and benefit from performance and feature enhancements.
By working closely together, our account teams can help you develop a multi-year plan that provides measurable cost savings opportunities due to system efficiency gains and consumable usage optimization. These strategic audits also help customers strategically sequence system upgrades of their older technologies to avoid the sticker shock created if your product identification equipment fails at the same time.
Our goal is to always to make it easy for our customers to make the perfect mark. Find the right product for your application by completing this short assessment.
Call us today at 800.722.1125 to learn more about how Diagraph partners with manufacturers to achieve product identification and packaging compliance success.
What does your company do when products are marked with the wrong product identification codes? Scrap? Rework? Mismarked and mislabeled products can create big hits to the bottom line. When encountering marking mistakes with regularity, companies can find it difficult to keep profit margins under control. What’s worse is if mismarked or mislabeled products make it out to market, manufacturers can face penalties from retailers and the risk of product recalls.
There are several factors to consider when trying to reduce marking mistakes:
The first step to reducing marking mistakes is picking the right coding technology for both your application and your manufacturing environment. When choosing a technology, some factors to consider include:
Available coding technologies include inkjet coders, labelers,thermal transfer printers, and laser coders. Each of these technologies have their merits and should be considered carefully with the help of experts familiar with the advantages and disadvantages. Success will be realized when the best technology is chosen for your unique situation.
Choosing the right technology often comes down to identifying the best possible combination of cost-per-mark and mark adhesion quality. There are numerous inks, label stock types, and ribbon formulations that can help you achieve a durable, lasting code on your product.
If you are marking onto a particularly tricky surface or operating your equipment in a hotter or cooler than average environment, you will want to run code adhesion tests and even demo the full solution for a period of time to ensure that code adhesion is strong once a mark is applied to your product packaging. A quality supplier will be able to run print samples and set you up with trials of their equipment.
Although choosing the right equipment and matching it with the right ink, label or ribbon is important, an often-overlooked aspect of achieving code compliance is material handling. Heavy vibrations in your production line and skewed products that are not presenting well to the coding technology can impact the overall quality of your mark.
Reviewing your material handling practices and making recommendations for the best use of your equipment is vital to achieving high quality marks on your products.
You can take your coding and labeling operation a step closer to guaranteed compliance by adopting a product verification or validation step after the mark has been applied to your product. There are several levels of verification that ensure that a mark:
Verification and validation require the use of scanners or vision systems as well as connectivity to your coding equipment and product databases.
When incorporating a verification or validation step into your coding and labeling operation, you will need some form of reactive material handling after verification takes place if a printed mark is considered to be illegible. When manufacturers encounter poor code quality, a signal can be triggered to stop the production line altogether to correct what is causing the poor print or a reject and redirect action can take place to separate the questionable product from the rest of production. If too many poor quality codes are encountered, production can be stopped to allow for a remedy.
Having issues with achieving packaging compliance and encountering too many marking mistakes? At Diagraph, we can help you quantify the true cost hitting your bottom line and will work with you to develop a game plan to minimize errors and ensure proper code adhesion.
TO CELEBRATE 125th ANNIVERSARY, DIAGRAPH INTRODUCES NEW GLOBAL STRATEGY
DEDICATED TO MAKING MARKING, CODING & LABELING EASY
World´s Oldest Coding Company Stays Modern with Strategic Shift Across All Aspects of Its Business
Diagraph Marking & Coding (www.diagraph.com), an ITW Company, announces the rollout of a new global strategy tightly focused on making package marking, coding and labeling easy.
Diagraph´s new brand identity focuses every aspect of the company´s business on providing hassle-free marking, coding and labeling for customers. This is achieved through an unwavering commitment to three core brand values – reliability, partnership and simplicity.
Far from an isolated marketing exercise, the new brand values represent the culmination of years of careful listening to customer priorities and a comprehensive top to bottom overhaul of Diagraph´s entire business structure. Moving forward, all aspects of the company´s business (including new product development, customer service, billing, delivery and human resources) are being driven by a shared commitment to providing products that are easy to use and being a company that is easy to work with.
Top to Bottom Brand Reorganization
As part of this new strategy, sister companies within the ITW Marketing & Coding Group will be rolled into the Diagraph brand.
Trident, the inventor of the world´s only repairable and longest lasting piezoelectric print engine, and Norwood inventor of the world´s first hot stamp imprinter for the food industry will become part of Diagraph Marking & Coding. The Trident name, respected worldwide and synonymous with rugged industrial design will remain the product brand name for piezoelectric print engines. Norwood Marking Systems will be completely consolidated into Diagraph with all new thermal transfer technology being produced under the Diagraph name.
This strategic focus on making marking, coding, and labeling easy will be rolled out across Diagraph’s operations worldwide, including Diagraph Mexico, Diagraph Asia, and Diagraph’s European operations through Allen Coding. Additionally, the Diagraph Global Partner Network of certified distributors will benefit from forthcoming products, programs, and services– extending the benefits of this new strategy to all Diagraph technology users.
Strategy in Action
In the weeks and months ahead, customers will see the launch of a number of new products, services and logistical enhancements all designed to make product marking easy.
Printing systems have been designed for market-leading uptime. Interventions are minimal, tool-less where possible and simplified with the goal of minimal touches for routine items like message editing, consumable replenishment and filter changes. New product development is focused on machine level communications and connectivity, with an emphasis on simplifying diagnostics and increasing uptime through preventive and predictive maintenance.
A comprehensive service offering underscores Diagraph´s desire to partner with its customers in all aspects of their coding and labeling operations, allowing customers to remain focused on their business. Service programs have been designed to match the skill level of customer maintenance teams.Levels range from "DIY" to "never lift a finger". Pro-active need anticipation and one-call-resolutions are guiding goals behind all service programs.
Additionally, customers will notice Diagraph´s new modern logo, updated visual identity and newly updated website (www.diagraph.com).
Context: 125 Years of Thinking Ahead
Diagraph, the world´s oldest product marking company, is celebrating its 125th Anniversary in 2018. The company has stayed relevant for over 100 years by anticipating industry trends and strategically realigning the brand to meet evolving market needs.
This approach has allowed Diagraph to remain at the forefront of global product marking needs with an impressive array of breakthrough technologies including: the world´s first stencil cutting machine (1893), the world´s first circular stencil cutting machine – the Diagraph (1902), the world´s first roll coder – the DiCoder (1969), the world´s first integrated valve jet technology (1986), the world´s first high resolution piezoelectric barcode print engine – Trident technology (1990), the world´s first centralized ink delivery system design for high resolution inkjet (1996), the world´s first automated cleaning system for high resolution inkjet technology (2002) and the world´s first all-electric automated labeling system platform (2008).
Diagraph´s new global strategic commitment to making it easy for manufacturers to make the perfect mark on their product represents a new chapter in Diagraph´s forward-looking leadership.