According to PMMI’s 2017 Trends in Food Processing Operations, “Four out of five companies have more than 100 product SKUs and over half predict SKUs will continue to increase, driving the need for faster changeover.”
A number of factors contribute to the drastic rise in SKUs, like company acquisitions and portfolio merging, flavor variety, count variety and retailer-specific case sizes, to name a few. Managing an increasing number of SKUs is costly for snack food manufacturers, especially when a bulk of them only contribute a small portion to their bottom-line profit. Constant starting and stopping of production lines to changeover a new product run means more downtime in a manufacturer’s operations.
On-the-go lifestyles, practiced commonly amongst the Millennial generation, have increased the need for convenient packaging:
A greater emphasis on healthy options has also increased the number of recipe variations, causing more SKUs to be made for tracking purposes. Consumers want to be able to recognize the ingredients in their products, known as “clean labeling”, giving rise to popular snacks like popcorn, breakfast bars, pretzels and others to have variations such as:
In addition to having access to ranges of food products in virtually any shopping setting – retail chains, convenient stores, grocery stores and department stores – consumers are also demanding to have the ability to order their snacks and other groceries online. Different distribution channels are assigned different SKUs for manufacturers to have visibility into tracking purchasing. On the fulfillment end of the supply chain, it is of the utmost importance that cases sitting in the warehouse of online distribution centers are clearly labeled with the correct product information to ensure accurate customer order fulfillment.
For instances when skilled labor workers do not speak the primary language of your printer settings, these barriers can be dealt with through advanced line setting features in the user interface of marking and coding technologies. More and more, interfaces for coders and labelers are moving towards the look and feel of a smartphone – with recognizable icons instead of text. For operations with multiple production lines to accommodate different products, the name of the product can be replaced with an image of the actual product for quick recognition. This simplified naming method for line settings reduces the user error brought about by language gaps.
There are a couple of levels in which SKU proliferation can be managed in an automated way through your coding and labeling printers:
1) Storing messages at the machine level with meaningful names to alleviate mistakes during changeover. For example, naming your message “Gluten Free Crackers” versus “Crackers”.
2) Message retrieval from a database through barcode scanning goes a step further through verification, ensuring that the message on the secondary cases matches the primary product information.
You can make the greatest impact on your operations, including managing SKUs, when you partner with a solutions provider to design your entire marking and coding operation around this objective. With your main requirements and unique specifications in mind from the start, it is possible to integrate a coding and labeling solution that not only works seamlessly in your production line but can add additional value by automating the SKU management process and reducing downtime.
Interested in more forward-looking trends and topics affecting manufacturers in the snack food industry? Download our free whitepaper, 2018: Innovations in Snack Food Packaging, for a full analysis of how these changes will impact manufacturers, packagers and retailers.
2018: Innovations in Snack Food Packaging
By Chris Pangallo, Product Manager – Continuous Inkjet (CIJ) and Laser
Production uptime and low cost of ownership are hot topics among Chemical production and Chemical packaging companies. Many Chemical companies rely on Continuous Ink Jet Coders (CIJ) to provide high speed non-contact coding of variable text such as date and batch codes on their primary product. Linx model CIJ printers are ideal for Chemical producers and packagers with a proven track record of reliability and increased uptime due to very clever design. The printers have mistake-proof and mess free refills, avoiding costly downtime.
Linx also features the most advanced printhead on the market. The printhead is sealed with no manual parts or adjustment points. Upon shut down, the printer automatically flushes the printhead conduit, nozzle and gutter with solvent. The solvent evacuates to the controller. This cleaning, known as Full Flush™, results in quicker start up, reduces ink build up and its’ accompanying printer downtime. Self-cleaning and quicker start up allows maintenance staff more time to work on production instead of their printer.
Chemicals can be packaged in all kinds of substrates and under a variety of conditions. A common challenge when coding in the presence of chemicals is the reaction of coding ink to the product, process or environment. Marks can smear, bleed or disappear entirely. Linx has developed special purpose inks that provide maximum print quality and increased printer performance by eliminating coding issues before they start. Here are some examples:
Detergents, shampoos and cleaners are among the wide variety of products that contain alcohol. With these products there will always be the risk of splashing alcohol onto the finished product during packaging. The alcohol splash can smear, obscure or even remove coding ink. Some products, like electronic components, require cleaning with alcohol as part of their production process. If you need an ink to withstand an alcohol splash, we suggest:
1075 Black Alcohol Resistant
This ink is formulated to have a high level of resistance to chemicals such as alcohol. It is fast drying (1-2 seconds) with excellent adhesion, particularly to plastics. It resists alcohol washes (ethanol, isopropanol, etc.)
If a packaged product comes into direct contact with a wash, splash or rub of a solvent (such as Engine parts, brake pads, cables), you will need an ink with high adherence properties. If you need an ink to resist solvents, we suggest:
1370 Black UV Cure
This is a black pigmented ink that cures instead of dries. When in the presence of UV lamp system, the ink cures in 1 second. The cured mark is supremely resistant to chemicals, abrasion and is tolerant of heat.
Many products have alkali baths as part of their packaging process. If you need an ink to withstand cleaning with alkali solution, we suggest:
1014 Black Plastic Adherent
This ink was formulated to give excellent adhesion to plastic substrates, including those commonly regarded as difficult for CIJ inks such as polyethylene, nylon, and polypropylene. This versatile ink has aggressive adhesion and is resistant to alkalis.
1070 Black Alkali Removable
This ink is highly water resistant when dry but is easily removed if washed with detergent or dilute alkali. It performs well on many substrates and is ideal for coding reusable containers in the brewing and beverage industries.
Products packaged in metals may have oil present on the surface. Oils tend to separate inks from substrates, removing marks completely. If you need an ink with aggressive adhesion, we suggest:
1290 Black to Blue Thermochromic
Thermochromic inks are specially developed for the canning industry and to show a color change effect when processed through a retort or autoclave process. It is a robust ink and often specified for applications that do not require a color change as it penetrates thin coatings of oil and grease and resists removal by oils, waxes, fats and varnishes.
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
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.
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.
At Diagraph Marking & Coding, we like to work closely with customers to understand the cycles of their business. This allows us to develop and recommend a personalized plan to manage maintenance schedules and on-hand supplies for their coding and labeling operations.
Cyclical account trends help predict and plan for the following:
We believe that customers are best served when we can partner in every aspect of their coding and labeling operations. This holistic approach allows us to maximize efficiencies while driving tangible value throughout a long-term partnership. Let us be the coding and labeling experts so you don’t have to be.
Interested in working with Diagraph to keep your marking, coding, and labeling operations running as easily and efficiently as possible? Speak with a Diagraph representative today by calling 1.800.722.1125 or contacting us through the website.
There is a great debate in the packaging technology industry around the core driver of automated labeling equipment. Which is a superior labeling power source — pneumatic air or electric? Pneumatic labeling systems are built around timing-based commands that drive label movements based on the reliability of the pneumatic air supply, while all-electric labeling systems are built around real time data-based commands that allow for total control of the labeling process.
The difference between the two approaches is night and day — like the difference between VHS and high-resolution digital streaming technology. The more that manufacturers understand the advantages of all-electric labeling, the more pneumatic systems will go the way of VHS tapes and rotary phones.
Every labeling system, regardless of core technology, can incorporate sensors for feedback. Recall the times you have seen a product strike a pneumatic labeler’s actuator arm while moving down the packaging line. This happens all too often with pneumatic labelers because the control of the label feed and actuator arm is not reacting to real-time feedback from sensors, it is following pre-programmed timing commands and relying on the programmed settings for the pneumatic air supply (regardless of the actual pressure in real-time).
Free from the timing control constraints found in pneumatic air powered machines, Diagraph’s all-electric labeling systems can interpret feedback from smart sensors in real-time to allow for total control of the label throughout transit. Combining strategically placed sensors with brushless DC servomotors allows Diagraph’s labeling systems to operate with extreme precision, guaranteeing one-to-one label-to-product matching time after time. The all-electric, servo-driven actuator maintains speed consistency, while “smart” sensors confirm that a label is present for application and even provide the ability to control impact on the product being labeled. The system doesn’t have to rely on inconsistent air pressure to manage this process.
Another advantage of the all-electric method over the pneumatic air method centers around the tamp pad. Pneumatic driven label applicators utilize venturi vacuum technology to control the transit of the label from the tamp pad to the product. Nearly the entire surface of a pneumatic machine’s tamp pad needs to be covered by the label to maintain proper suction. Unlike pneumatic machines, Diagraph’s all-electric label applicators utilize an electric fan to create vacuum, allowing Diagraph labelers to accommodate multiple label sizes utilizing a single tamp pad. This saves time during label size changeovers as well as money.
With more than 120 years in the marking and coding industry, Diagraph has a rich history of providing highly durable and reliable labeling and inkjet solutions. Diagraph was the first to offer all-electric labeling solutions to handle all modes of label application including tamp, swing and tamp-blow. The result is a robust lineup of automated labeling solutions that offer benefits only found in all-electric systems that don’t compromise on labels sizes or performance.