Plant managers and maintenance managers alike are deserting pneumatically driven label applicators in favor of all-electric label applicators for one BIG reason – dirty air lines.
Unpredictable, unfiltered air supplies disrupt the efficiency and performance of air supported tools and machinery, especially label applicators. Water, oil and particulate matter are hard on label applicators, impeding the performance and reliability of the tamp pad suction and the actuator arm – the key functionality of any automated labeling machine!
With all of this being said, not all electric label applicators are created equal! Contact us today to learn why Diagraph printer-applicators and label applicators lead the industry in both reliability and performance.
To achieve packaging compliance, manufacturers need more than picking the right product coding technology. Data management and packaging control and automation add another level of sophistication to an operation’s compliance practices.
Incorrect manufacturing codes can be applied to products due to human error or improper material handling practices. But manufacturers can rely on data connectivity and good data management practices to handle variable print message editing and selection.
Data management is part of Industry 4.0 -- by using data management and connectivity to manage data integration on the production floor, manufacturers can automate the correct information being printed on the correct products, which is an important step in ensuring packaging compliance. Specialized printer management software can make this process seamless.
One-way data management allows manufacturers to use existing databases to automatically fill in data for print message formats. The populated codes are sent in real-time directly to the printer. By using a central database to link and populate batch, date, and barcodes, user error can be minimized.
Manufacturers can use two-way data management to receive feedback in real-time that will allow them to improve their operational processes:
Making sure the right manufacturing codes are being printed onto products is one half of the printing process. The other half is to make sure that the packaging substrate is presented consistently to the coding technology to be printed upon. Among other consequences, improper material handling can lead to codes being printed inconsistently and incorrectly.
Material handling measures that can minimize printing errors include:
However, even with these measures in place, incorrectly printed products can still occur. Which is why it is important for material handling reject systems to be in place in order to detect non-compliant products before it reaches the retailer, or more so, the consumer. Packages with incorrect codes printed on them can sometimes have the opportunity to be reworked with the correct manufacturing codes instead of being scrapped completely, which is a less than ideal situation from a production throughput and financial standpoint.
Some features of reject systems can include:
And by evaluating the material handling processes regularly, the processes can be improved over time so fewer packages fail packaging compliance in the first place.
For manufacturers to achieve packaging compliance, implementing data management and good material handling processes are recommended, along with using the right product identification solution.
Working with a partner that has an understanding of material handling best practices and how to utilize data management to optimize operations can help manufacturers better achieve packaging automation. Manufacturers should also seek out partners that offer a variety of product identification solutions, support beyond installation of equipment, a network of conveyor and vision system partners to create turnkey solutions and training for maintenance staff. The combination of all these factors can set up manufacturers for success in packaging compliance.
We hope you’ve enjoyed our blog series on how to achieve packaging compliance. Check out the other posts here:
According to a recent PMMI Business Intelligence Report, the meat, seafood, and poultry packing industries are experiencing “a global boom” due to several factors including import and export opportunities expanding into new markets, growth in foodservice, and growth in ready meals. Food producers are rapidly moving to automate processing and packaging to be prepared to meet increased demand and be flexible enough to adapt to changing product coding requirements.
For food producers and processors with small character coding requirements, Diagraph offers the Linx 8900 Series Continuous Inkjet (CIJ) printer family. The 8900 Series is designed for maximum uptime and provides the flexibility to meet the demands of complex food manufacturing plants.
Moving towards an automated continuous inkjet coding solution can solve the following problems commonly found in the meat, poultry, and seafood manufacturing industry:
High manual labor costs: Consumer demand dictates changes in the packaging materials used for meat and seafood products. Flexible and clear packaging for shoppers to verify freshness and quality in-store, smaller portion sizes and clean labeling to indicate product varieties – i.e. GMO-free, grass-fed, etc. – leads to more changeovers and a need to produce high-quality, durable codes on a range of substrates. The costs associated with managing a large manual workforce are cited by many manufacturers in this industry as one of the highest expenses. Manufacturers are looking for automated processes that can be run with little to no training required and an easy-to-understand HMI to make product changeovers as effortless and error-free as possible.
How the Linx 8900 meets this challenge:
Food safety and sanitation issues: Threats of contamination are a constant worry in the meat, poultry and seafood industries. To integrate new automated machinery requires that the process reduces human handling and has clean-in-place and washdown capabilities.
How the Linx 8900 meets this challenge:
Maintenance downtime: Manufacturers want to continue to increase their throughput to fulfill growing demand. To keep production going, predictive maintenance features are essential in preventing unexpected shut downs for repairs, printhead cleanings or fluid refills.
Are you facing these challenges in your business? If you’re in need of a date, lot or batch coding printer, the Linx 8900 Series might be the right option to help you efficiently automate your meat, poultry or seafood packing operation. For more information, visit our Linx 8900 Series product specification page or arrange to see it in action by contacting us for a demonstration.
Source: PMMI Business Intelligence Report, 2017 Trends Shaping Meat, Poultry and Seafood Packaging and Processing
Automated Pallet Marking System
The American Lumber Standard Committee recently imposed a regulation on companies that produce heat-treated pallets. This regulation forces pallet manufacturers to mark each pallet with the IPPC HT logo. As you can imagine, many issues quickly surfaced with this addition including poor quality, a loss in productivity and an increase in labor costs for many companies.
Many facilities rely on manual stenciling to apply this logo, as well as other identification and tracking data. Not only is this time-consuming, but it also requires the use of manpower with inconsistent results. Here at Diagraph we came up with a better solution.
The IJ3000 Large Character Ink Jet Printing System addresses and corrects these issues.
Despite the best intentions, manual anything often leads to inconsistencies. For businesses with a brand image to protect, this poses a problem. The automated IJ3000 removes the need for manual marking and delivers uniform results.
Loss in Productivity
Relying on manual labor always runs the risk of human error. With pallets, this could mean incorrect stamping or lower than needed speeds. This system produces simultaneous online marking for both sides, as well as automatic printhead cleaning. These features lead to an increase in production as well as less downtime for maintenance.
With the necessary printing of lot codes, production dates and other relevant information, the need for labor increases. This adds extra costs that an automated system such as the IJ3000 eliminates.
To learn more about how the IJ3000 Pallet Marking System can increase productivity for you, learn more here.
Diagraph, An ITW Company, announces the addition of ITW Inks to its wide range product offering. Formulated for use in Marsh Ink Jet Printers, ITW Inks provide a cost-effective ink alternative that is low on price and high on value.
Click here to find out more about ITW Inks...
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 firstname.lastname@example.org.
During the COVID-19 pandemic, manufacturers in essential industries such as food, hygiene products, and medical supplies are needed more than ever. It’s critical that these products continue to be produced and shipped in a timely manner, to support the growing demand. Current manufacturers are doing the best they can to keep their production up at this time. And moreover, companies in industries from cosmetics to breweries to sustainable clothing are pivoting in the face of the COVID-19 disaster.
But maintaining or increasing production to meet demand during this time, while vital, also brings challenges -- including gaps in the supply chain, dealing with new and heightened hygiene and safety requirements, and navigating new packaging compliance requirements during a company pivot.
There’s no place on the planet that is not being impacted by COVID-19. With the globalization of manufacturer supply chains over the past several decades, this means that almost no supply chain will be unaffected by the crisis. Freight shipping has been drastically reduced in an attempt to help slow the spread of the virus. Truck driver shortages were already being reported before the spread of COVID-19, and now the demand for their services has only increased. With shelter in place orders, regions closing and opening on an unpredictable schedule, facilities having to follow quarantine restrictions, even essential manufacturers will be seeing shifts in their businesses.
To further complicate matters, supply chain disruptions cause food that is desperately needed to instead be wasted, as perishable food products are unable to reach market. Milk, for example, has been hit particularly hard already, as the U.S. government has been asking dairy farmers to dump their supply. Meat and produce can be frozen, grain can be moved into siloes, but milk and many other dairy products cannot be kept from spoiling over the long term and those dairy farmers are scrambling to pivot their bulk production to retail packaging.
Your company will be dealing with many potential points of failure across the supply chain. And there are more challenges to overcome as well.
Food, medical supplies, and other essential industries cannot afford to cut back production like other industries. But the workers in these industries are already seeing a much higher rate of infection than the general population. In North Carolina, 23 meatpacking plants have reported outbreaks, with more than 1,300 workers testing positive for COVID-19. And a meatpacking plant in Minnesota has reported almost 200 cases among its workers.
It’s more important than ever that companies implement good hygienic practices to keep workers safe. Proper deep cleaning procedures and 2-week quarantine periods can take time away from the production output of goods or shut down a plant all together. However, these measures ensure the health and safety of essential employees who are mission critical to meeting production demands that fuel the economy.
A number of companies in non-essential industries are pivoting to provide essential supplies during this crisis. Breweries and distilleries are producing and shipping hand sanitizer, due to having the majority of the ingredients already in-house. Meanwhile, restaurants are selling groceries, and the dairy farms that previously sold in bulk are switching over to serve more direct retail clients.
But switching over production means new compliance requirements. Additionally, processing and coding technologies that worked well for previous product needs may not be suited to print on new substrates. With so many challenges being faced, how can manufacturers keep up? Luckily, it can be fast and easy to shift to a new product coding solution.
Small character inkjet coders, for instance, are a great solution for manufacturers wanting to add new printers on their line or for those manufacturers who have switched over to packaging hand sanitizer or more retail packaged foods. Alcohol resistant inks are even available to ensure proper code adhesion even on hand sanitizer products or to withstand more rigorous cleaning procedures. More advanced continuous inkjet systems have simple set-up requirements, making self-installation achievable for facilities keeping a lockdown on visitors.
And in this time of economic uncertainty, manufacturers can lease coding equipment, spreading out payments instead of having to spend a large amount of capital upfront for new printing systems. For operations requiring consumables like inks, ribbons or on-the-shelf spare parts, supplier partners can work up blanket contracts to ensure savings over the long-run. There are multiple ways manufacturers during this time of crisis can meet current and new coding demands in a cost-efficient way.
The landscape of business everywhere is changing rapidly and even essential business manufacturers will be feeling the impact of these changes.
Your company will be dealing with many challenges during this time -- potential points of failure across the supply chain, the dangers of pivoting, rigorous new safety and hygiene requirements. Don’t let your product coding be one of these new challenges. Not when the solution can be so simple. Talk with a Diagraph Marking & Coding consultant to understand your options if you’re being met with coding challenges in your production and we will help you understand your solution options and how to implement them.