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.
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
Download the full whitepaper, “Pallet Labeling: The Final Step In Your Production Tracking Process”
The final step in your production process can often easily be overlooked. After rigorously completing all the upstream processing, packaging and coding processes, the final palletized product seems to be a small step before crossing the finish line. However, labeling at the pallet level is a crucial process for identifying palletized products being shipped to retailers.
Imagine this: You’re completing a custom job for products specific to one regional retail chain. To differentiate the pallets for the custom job from your standard products, you plan on printing the identifying batch information on the license plate label and applying it to the outside of the shrink-wrapped pallet. When the time comes, your shipment is sent to the retailer only to discover that the products sent are not the custom printed containers they ordered. Now not only is your relationship with this retailer tarnished, but you are on the hook for reprinting all of their products at your own cost.
This scenario might sound familiar if you’re still in the business of manually applying labels. Some level of human error is always a risk and it can be a costly one. Ensuring a consistent, accurate label on every pallet that leaves your facility doesn’t have to be a trying task. It is possible to guarantee proper label placement while also avoiding common safety issues often occurring from the entanglement of the labeler in the pallet shrink wrap.
Our pallet labeling experts at Diagraph have complied a helpful guide for assessing automated pallet labelers for your production line. This guide steps through the main questions you should ask when evaluating your pallet labeling automation process and reviews the top areas of consideration you should work through before you make any kind of investment.
Download the full whitepaper, “Pallet Labeling: The Final Step In Your Production Tracking Process”, here to learn more.
Pallet Labeling: The Final Step In Your Production Tracking Process
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.
If you’re a manufacturer integrating traversing CIJ and thermal transfer overprinters in your form, fill and seal machines, consumables contribute to your total cost of ownership in a major way. You may identify with some of the following common pain points related to coding onto flow packs, plastic sleeves and sachets, and it is crucial to your profitability to find a solution for overcoming these issues:
There are alternatives available to you to avoid these common pitfalls in multi-lane coding operations. Look for these two features in your system to minimize parts, fluids and ribbon costs in the long run:
1) A single consumable – To avoid the mess and additional training, specifically evaluate options using a single roll of ribbon for all of the print heads.
2) Ribbon saving mechanisms – Once you have evaluated a multi-lane coder with ribbon instead of ink, ask about ribbon saving mechanisms. Industry-leading applications ensure minimum gaps between prints and can result in up to a 50% reduction in ribbon waste.
Are you in the process of evaluating multi-lane printing and coding technologies to meet your unique form fill and seal machine requirements? Download our free Hidden Costs of Multi-Lane Printing guide.
The Hidden Costs of Multi-Lane Printing Whitepaper
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.
The Industrial Internet of Things (IIoT) is transforming manufacturing and a whole host of other industries. IIoT connects industrial devices that can monitor, collect, exchange, and analyze data, and leverage that data and connectivity to help you make smarter, faster and more effective business decisions.
Chances are, you’re already automating parts of your business -- but IIoT takes automation to a whole new level. Two major IIoT trends to watch for in 2020, according to Mobidev, are wireless connectivity and predictive analytics. If you aren’t leveraging IIoT as part of your marking and coding process, it’s a wasted opportunity.
Centralized printer management software connects wirelessly to your printing and coding equipment, creating a central database so that operators can review printing status and start jobs remotely using their mobile devices – among other capabilities. Centralized printer management software can also track prints and analyze operational history, to deliver valuable insights about your processes.
The robust interconnectedness of IIoT technology such as a centralized printer management system, can innovate the product identification process in a number of ways. For example, imagine being able to run your production processes without having to constantly keep an eye on your coding and labeling equipment.
Some other benefits of centralized printer management software include:
Here’s a checklist of common complexities and pains that manufacturers experience with production. If any of these experiences sound familiar, you could benefit from deploying printer management software in your facility:
Improving manufacturing processes is an ongoing challenge, and IIoT can help. For your marking and coding process, centralized printer management software offers many benefits and seamlessly automates a complex operation.
Take the next step to automating your coding and labeling operations. Try NEXTConnect™ printer management software for free for 90 days. Contact a Diagraph representative today at email@example.com for a trial license.