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There is no escaping the fact that nearly everything, including energy, raw materials and labor, is increasing in price. That is why it is critical to consider the total cost of ownership (TCO) when purchasing a new coding solution. Purchasing a lower cost coding solution that has high hidden costs will result in a higher TCO down the line.
Let’s take a car purchase for example. The initial purchase is not the end of your costs. Fuel and/or electricity, road tax, servicing and unexpected breakdowns, maintenance, insurance, and roadside assistance are all additional costs that will be incurred.
The same is true for industrial printers. The machine price is not the only consideration. So, how can you work out your TCO over a printer’s lifetime to get the best value? Diagraph’s TCO calculators can show your TCO costs for continuous inkjet (CIJ) or laser coder. Contact us and let us crunch the numbers so you can make the best choice.
You can help reduce your TCO for industrial printers
There are ways you can save costs when purchasing new coding equipment. If you are thinking about a CIJ system, consider the following: ⦁ Does the model you are considering have long service intervals and self-service as an option? ⦁ Is the user-interface intuitive? ⦁ How much training is needed ⦁ Do the required training and maintenance minimize human error and keep costly rework to an absolute minimum?
Don’t forget about consumables. Our fast-drying 1240 ink for CIJ coders will support 40% of all applications, meaning less stock control for you. Plus, the innovative upside-down ink cartridge design ensures you’ll use every drop.
In contrast, laser coders use no ink or solvents. The robust design and tube life also gives Linx coders longevity, boosting output efficiency while keeping costs down. If have high production volumes or using a coder that consumes high volumes of ink, a laser coder could be an excellent option for you to consider.
Coding is a CRAFT
Top 3 Tips for Choosing a Coding Provider
It can be difficult to choose a marking, coding and labeling equipment provider with so many available. These tips will help you find the best provider for your business:
At Diagraph, we are dedicated in solving your coding and labeling challenges. Diagraph has been assisting customers for over 120 years improving production line efficiencies with simple, reliable, cost-effective coding and labeling solutions. Visit us at www.diagraph.com or contact us at 800.722.1125.
Analogue coding technology is still found throughout the meat processing industry, such as hot stamp or roller coders. As a relatively cheap printing solution, these could be used by meat processors to keep costs down on their fast production lines.
Of all the analogue coding technologies available, hot foil stamping is perhaps the most common in meat processing. Our best-of-industry Norwood hot stamp printers are still widely used today. With that being said, relying on analogue based technology can have its drawbacks, and that’s where digital coders come in.
The drawbacks of analogue coding technology
When it comes to analogue coding, the messages that are available for coding are restricted by the amount of information that can actually fit on the die wheel. Therefore, the coders are not as flexible as they could be when it comes to having to incorporate larger messages on the pack. Also, with hot stamp technology, there is a wait for the coder to ‘warm up’ – meaning that valuable coding time is lost through setup.
In an industry dealing with fresh produce where packers need to respond to changing legislation quickly and efficiently, having a technology that needs this amount of time to set up is not ideal in many meat processing lines. Also, errors in coding cannot easily be amended, as codes are manually changed on the die wheel which means stopping the printer, removing the die wheel and replacing individual characters which is a fiddly and time-consuming process. Worn code wheels can also potentially lead to perforation of the packaging, something that could potentially lead to scrappage.
Hot foil stamping is also a contact technology, something that could further constrain the speed of the production line, and even present packers with problems when it comes to maintaining the hygiene of their line.
Digital coding and marking technology in meat processing
SmithersPira has recently examined the benefits of digital coding for many industries including food manufacturing. Their analysis of other industries helps to highlight the advantages of digital coders within the meat processing sector.
For example, when looking at drug production lines, the requirement for frequent and error-free changeovers would appear to be a driver towards the implementation of digital technologies. This is no different in the meat processing industry, where errors in coding could lead to potentially costly downtime or scrappage.
The research also identifies how digital coders can help packers deliver consistent traceability. With late-stage customization for example, when codes need to be added or changed at the last moment, flexibility becomes a primary concern for packers – something that is not delivered as effectively with analogue coding technology. And with a reduction in errors as mentioned above comes more effective traceability.
Not only can all of this be delivered by digital coders, but the non-contact nature of the machinery can help to maintain hygiene and even deliver codes at faster speeds.
Therefore with fewer errors, flexibility, and faster, more consistent coding, digital technology represents a more cost effective solution for meat processors in the long term. And with uncontrollable variables such as adverse weather events, disease outbreaks and increased competition from seafood, meat processors need to deliver codes in an effective way that allows margins to be maintained.
To discover more about what digital coding technologies are suited for the meat industry, have a look at our meat processing industry white paper.
Want help analyzing the best use of analogue and digital coding technologies in your meat packing facility? We manufacture, sell and service both analogue and digital coding solutions. We work closely with customers like you to determine which coding solution is right for your manufacturing environment and application needs. Contact us today to get the conversation started.
Read a version of this article specific to European meat and poultry manufacturers.
System uptime is the average length of time a piece of equipment runs between interventions are required to keep it operating smoothly. When comparing system uptime when assessing coding equipment, it is important to look at several factors including:
To understand system uptime better, let’s take a closer look at each of these key areas:
Consumable replenishment is the most common and necessary interaction with any given piece of coding equipment. The amount of time a system can go between consumable replenishment, like adding more ink to an inkjet coder, replacing ribbon stock in a thermal transfer printer, or replacing labeling stock on a labeler largely depends on the capacity of the individual piece of coding equipment. There are additional factors to consider when assessing consumable replenishment.
For inkjet coders, it is important to understand how long a printer can run after the bottle or cartridge of ink has run out of fluids. Does the system provide an advanced notice warning giving a countdown to when the coder will be truly empty? Does it provide enough of a warning that allows for fluids to be replenished at ideal production times like before and after shift changes? Can the fluids be replaced while the system is actively coding?
For thermal transfer printers, ribbon capacity as well as total ribbon usage are important to maximizing the length of time between replacing ribbon stock. For ribbon capacity, look at the maximum size of the ribbon roll for your chosen ribbon type. To maximize ribbon usage, look for thermal transfer printers that offer ribbon saving features that utilize as much surface area of the ribbon before advancing it for ribbon waste collection.
Although replenish consumables is unavoidable for the most common types of coding equipment, the very act of replacing or replenishing a bottle of ink or solvent, a roll of ribbon, or a roll of label stock can be made easier and less time consuming for system operators.
Inkjet coders tend to be the easiest type of coding equipment when it comes to consumable replenishment since most inkjet coders can keep running while being refilled. Look for inkjet coders that offer mess free, mistake free refill options like needle and septum systems that prevent leakage and dripping when swapping fluid bottles. This is ideal compared to inkjet coders that require fluid bottles to be manually poured into the system. Another factor to consider is how many touches or actions are required to complete the fluid refill process. Look for systems that provide one-touch fluid refill options as well as variations in shapes and sizes between ink and solvent bottles to simplify the process as much as possible while preventing the wrong fluids from going in the wrong compartments.
Due to the nature of thermal transfer printing, the printer will become temporarily unavailable for coding while ribbon stock needs to be replaced. Look for thermal transfer printers that have an easy-to-web design as well as easy to remove and replace ribbon cassettes. Investing in an additional ribbon cassette that can be loaded and ready to go when ribbon is low minimizes downtime on thermal transfer printers as much as possible.
Like thermal transfer printers, automated labelers also become temporarily available for use when label stock needs to be replaced. Look for an automated labeling system that has an easy label webbing design to make it easy to unload spent stock and load a fresh roll. Manufacturers with high production commands benefit from having alternate labeling machines available. When one machine signals that its label stock is low, the other starts applying labels so that the low system can be replaced. This virtually eliminates downtime with automated labelers.
Although consumable replenishment is required more frequently than maintenance, preventive maintenance procedures take more time to complete and often require the coding equipment to be completely unavailable for printing while being serviced. Not all coding systems are created equal. Service intervals are usually stated in the amount of system hours that can pass before preventive maintenance is required. Things like ink type, manufacturing environment, and overall wear and tear caused by the application can impact recommended system intervals.
For inkjet coders, look for systems that can run as long as a year or more before maintenance is required. Better yet, look for systems that provide advanced warnings about upcoming maintenance so that you can schedule interventions around your production schedule. Another factor to consider is how easy or complicated it is to perform maintenance. Look for systems that have self-contained service modules that can be easily swapped out without the need for a service engineer. Systems that have screen-guided instructions for service interventions tend to be the easiest to use.
For thermal transfer printers, take a look at preventive maintenance requirements that are recommended by the manufacturer. How many parts require replacement? How long does the manufacturer state it will take to perform maintenance? How easy is it to access parts that need to be replaced? These are all important questions to ask when evaluating thermal transfer printers.
When it comes to automated labeling systems, all-electric systems allow you to replace wear parts while relying on pre-programmed settings to get the labeler operating as quickly as possible. Pneumatically operated labeling systems require extensive adjustments after replacing wear parts, making maintenance interventions anything but fast. Also look for labeling systems that offer screen-guided instructions for quick and simple service interventions. Another advantage of all-electric labeling systems over pneumatic is that electric options allow for a gentler application of the label to the substrate. This cuts down on overall wear and tear, allowing the system to go for longer between maintenance intervals.
If you have any questions about how to calculate the uptime of your current coding equipment compared to new coding equipment technology, we are here to help. Contact a Diagraph product identification expert today by calling 1.800.722.1125 or contacting us through our website.
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
Seasonal Coding Tips
By Chris Pangallo, Product Manager – Continuous Inkjet (CIJ) and Laser
Many manufacturers in food processing and consumer goods experience seasonal fluctuations in demand. As a result, their production must ramp up and down throughout the course of the year. Should their product require variable coding such as batch codes and date codes, these companies often make use of Continuous Inkjet (CIJ) coding technology.
Reliable Coding
Companies that need reliability in their product coding both in peak and off peak production often turn to Linx CIJ printers. All Linx CIJ coding solutions feature a hermetically sealed and potted simple design ink jet printhead that cleans itself. Linx customers experience greater uptime as they do not have to align the ink jet or constantly clean their printer for best print quality. Linx CIJ printers are offered in stainless steel IP55 or IP65 rated enclosures suitable for wash-down and dusty environments. Linx also offers a broad range of fluids to ensure quality marks on a variety of substrates.
The following coding tips will help you plan for the challenges of seasonal production:
Ramping Up
Encoding
If product output needs to increase, the production lines may be running at higher, variable speeds. To ensure quality marks it is recommended to provide a speed signal to your CIJ printer. The printer will adjust drop output to match the line speed, keeping the message from stretching out. Line speed measurement is commonly achieved with the addition of an encoder. The encoder mounts to your conveyor and the rotation of the encoder wheel signals the printer as to how fast the production line is moving so that printing output can be adjusted on the fly. In addition to preventing message stretch, the signal will also keep the message from contracting when the production line is moving at a slower rate.
Software Upgrades
If a customer has standard CIJ printers and finds that its production line speed exceeds the printer’s capability, do not panic. Linx offers software upgrades that customers can install themselves. The software upgrade for a higher performance message type is achieved with a Configuration Code. When entered into the printer higher speed printing is enabled.
Consumables ordering
When planning increased productivity, don’t forget to take inventory of your coding consumables. Place appropriate orders for ink & solvent and arrange for Preventative Maintenance filter changes based on expected usage.
Ramping Down
Decommissioning
Linx customers have a great benefit with the automatic print head cleaning feature known as FullFlush™. At the end of printing, simply hit the Stop button. The printer will engage a solenoid to shut off ink to the nozzle and then flush the printhead and its tubing out – through both nozzle and gutter- with solvent. This leaves the printhead clean and dry and ready to start when next needed.
Planning for a few weeks of downtime
If there is no need for CIJ printing for a few weeks, many customers keep the printer in the production area and will start the unit in the morning and turn it off at night once or twice a week. This keeps the fluids from settling within the ink delivery system and ensures a good start up when they need it.
Planning for downtime that extends beyond 6 weeks
If production completely shuts down for an extended period of 6 weeks or more, decommissioning of the CIJ printer should be considered. Decommissioning involves removal of fluids from the printer and a change of filters. This eliminates the concern of solvent evaporation or ink thickening within the ink delivery system while your printer is in storage.
It is clear that cyclical production provides many challenges, but all of these challenges can be addressed head on with the innovations in the Linx CIJ product line.
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.
Brand Values
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.