Coding sweet success
John Tierney evaluates the trends, challenges and opportunities in labelling and coding.
The confectionery sector remains fiercely competitive with companies continually seeking to innovate and diversify in a fast-moving, packed market. Packaging manufacturers have also had to respond to these developments – for example, the trend towards recloseable bags and tubs of bite-sized chocolates has brought demand for different types of packs, in addition to the traditional paper or card outer wrapper.
Different packs and shorter production runs create other challenges for manufacturers, with the requirement to maximise flexibility on the production line, while maintaining efficiencies and output. The need for fast changeovers, and to switch production, machinery and staff between lines increases the potential for expensive errors, both in terms of downtime and wasted product.
Coding and marking equipment can play a small but vital role in supporting the efficient running of the line. Code requirements may be simple and driven by legislation – usually a best-before or use by date, batch code or other identifier – but stringent food regulations and the cost implications and damage to brand reputation of a product recall mean this is something no manufacturer can afford to get wrong.
Research by coding and marking solutions provider Linx Printing Technologies has indicated that fast-changing confectionery production environments increase the likelihood of operator error, especially where staff may be unskilled or temporary, with a high turnover. For this reason, manufacturers and packers need to rely on their equipment’s ability to perform its basic task.
The selection of the most appropriate coding and marking equipment can therefore be critical; for example by choosing machines that are capable of storing many different messages of various types that can be changed quickly, or with easy-to-use picture-based interfaces, which minimise the likelihood of error; or even where several machines can be controlled or monitored remotely from a computer or smartphone.
Coders also have to be capable of delivering quality print at varying line speeds without loss of integrity, especially at peak production times such as Easter or Christmas when the pace of production is crucial. Equally important is the ability to move a printer easily from line to line, according to production demands, and this may be an important selection criterion.
For specialist manufacturers seeking to increase production or secure their first order from a major retailer, code quality will be vital and may require a step-up from less flexible, non-digital coding methods such as print and apply labelling, stamping or hand applied labels. An entry-level coder that can deliver the necessary quality may provide the ideal starting point.
At the other end of the scale, for manufacturers with numerous product lines and a healthy new product development programme, future-proof coders, which allow add-ons to be integrated at any time, mean users can react to changing trends quickly without having to trial, test and gain expenditure approval for more machines.
In crowded markets with many products jostling for impact on shelf, every millimetre of the packaging is valuable as a carrier of branding. This means the area where the code has to be printed may be small, further driving a need for accurate, mistake-free coding into tight spaces and at different angles – on the side, top or bottom of a container.
Reliability is a given for any production line, so coding machines must be able to deliver straight from start-up, with the first print as good as the last. Printers with self-servicing options can minimise downtime for scheduled maintenance and the expense of an engineer call-out. In environments where hygiene is essential, coders must operate cleanly, with the ink delivered where it is needed and not on the floor or the production line.
Factors to consider
There is a wide choice of coding equipment available for the confectionery market and choosing the best solution will obviously depend on the particular requirements of individual applications.
Typical factors that need to be taken into consideration will include the code content, substrate to be printed on and the speed of the line. Coding conditions may also be an issue – a wet or dusty factory environment will require a printer with the appropriate IP rating.
For primary packs, the main choice will be between laser coding and CIJ (continuous ink jet) printing. Laser has no ink involved in the coding process and therefore no drying time and no risk of smudging, which can be an issue on some materials where the coded product is in contact with other products or handling systems soon after coding.
Laser coders are suitable for a wide range of substrates at any line speed, and can also produce high quality graphics and logos over relatively large print areas. They are particularly attractive due to low down-time, high-speed capability and the fact there is no use of consumables.
CIJ can print on almost any substrate, including metal tins, from one to multiple lines of text and simple graphics at speeds of over 2,600 characters per second. A wide range of inks, including different colours and food grade options, is available. The compact printhead can be situated above, beside or beneath a production line – even traversing from side to side across the line if necessary. With lighter models increasingly being produced, the CIJ printer is more capable of being quickly moved from line to line and is quick to install and set up.
For secondary packaging requirements, case coders are particularly well-suited for printing variable information onto a variety of surfaces and materials, while Thermal Inkjet Printers offer a flexible coding solution for both outer cases and primary packaging and are a cost effective solution for slower production lines or where production is not 24/7.
Linx research has also found that many users prefer a simple, cost-effective solution rather than complex, feature-heavy machines. Nevertheless, a printer where additional features can be added as required will provide the flexibility to respond to market developments or increased business.
One important consideration in any purchasing decision is the overall cost of ownership of the equipment. This takes into account the initial purchase price, plus the consumables and servicing costs over years, as well as the hidden cost of downtime caused by an unreliable printer or delays in code entry during changeovers.
Coding is a necessity for confectionery products, but the selection of the right coder can provide valuable support to a company’s efficient manufacturing and packing operation.
Author
John Tierney is marketing director at Linx Printing Technologies.
