- Anne Marie Mohan, Senior Editor

A new thermal-transfer overprinter combines with a vertical pouch machine at Farmdale Creamery, Inc. to help the dairy deal with rising resin prices for its sour cream packaging. In addition, new ink-jet printers provide more flexibility for coding containers and cases.
In recent years, plastic’s use in food packaging has far outpaced that of its can, paperboard carton and glass counterparts. Last year, The Freedonia Group, an industrial market research firm in Cleveland, reported that plastic pouches and bags made up 39 percent of the $17.7 billion food-container market, while rigid plastic containers comprised 15 percent. In contrast, only 23 percent of food packaging was made of paperboard, 18 percent of metal and 5 percent of glass. Among the advantages plastic packaging can offer are enhanced barrier properties, resealability, flexibility, a lighter weight and high-impact graphics, among others.

However, in today’s present environment of unstable fuel costs, the advantages of plastic packaging come at a cost. Derived from petroleum, or natural gas, plastic resins have increased tremendously in price in 2005, and there seems to be no relief in sight.

It is because of this volatile economic atmosphere that San Bernardino, CA-based Farmdale Creamery, Inc. equipped itself earlier this year to reduce the amount of polyethylene used in its sour cream packaging, by moving some of its product packed in rigid plastic containers into plastic pouches. “With the price of oil increasing, resin is now more expensive, and this affects the cost of plastic containers and bags,” relates Norman Shotts, Farmdale’s systems engineer and grandson of the company’s founders. “But there’s so much more resin in a plastic container. To offset that, we are using bags to save some money.”

Farmdale’s staple product, however, is sour cream, which it produces in a traditional, gelatin-based version, as well as in Russian, Hispanic and kosher varieties, in package sizes from 1/2-pt containers up to 32-lb bags and buckets. Farmdale offers its own brand of sour cream “in most sizes,” says Shotts, as well as copacked product prepared according to private-label customers’ recipes. The larger-volume packs are targeted at bakeries, restaurants, dressing manufacturers and others.

Farmdale uses four packaging lines to fill its range of sour-cream products. One handles pails; one packs 5-lb buckets; one fills smaller, retail sizes, such as 1/2- and 1-pt containers; and the newest line fills plastic pouches in sizes from 16 to 32 lb. The pouching line, running since last spring, comprises a Cryovac(R) Onpack Model 2100 vertical form/fill/seal machine from the Cryovac Div. of Sealed Air, equipped with ID Technology’s intermittent TTO.

The automated, vf/f/s machine creates pillow-style pouches in volumes from 1.5 to 5 gal; Farmdale uses it for 16-, 25- and 32-lb bags of sour cream. The pouch film is a polypropylene construction from Cryovac.

Per Cryovac’s recommendation, Farmdale installed ID Technology’s TTO in-line on the vf/f/s machine in order to cleanly and clearly add an expiration date, a batch number and Julian date information to its sour cream pouches. As Shotts relates, there were several requirements that the printing equipment had to meet before being considered for the dairy packaging application.

“The main requirement was that the ink have good adhesion to the bag, which is why we chose thermal transfer—it’s more permanent. The ink is very difficult to rub or scratch off, whereas ink-jet printing would not work in this application,” Shotts explains.

During thermal-transfer printing, a printhead containing resistive elements in a linear array heats ink- or resin-coated ribbons. In this process, the printhead is in direct contact with the uncoated side of the ribbon, while the ink-coated side is in direct contact with the printing surface. When the ink is heated, it melts and adheres to the printing surface.

Last May, Farmdale installed a new vertical form/fill/seal machine for filling sour cream bags. Vital to the line is a new, in-line, thermal-transfer overprinter (TTO) from ID Technology that applies essential product information, including a batch number and an expiration date for the perishable product, onto the pouch.

In addition, to enhance the consumer’s experience with its sour cream containers, Farmdale began the installation in August of several continuous ink-jet printers, also from ID Technology, that move product coding from the bottom of the bucket to the side, while increasing legibility.

Family-owned Farmdale has been in business since 1979, supplying sour cream, buttermilk and cheese to an assortment of end users. In its 90,000-sq-ft facility, the dairy packs cheddar, jack and low-fat cheeses in 44-lb blocks under its Taco Lada and Lada Jack brand names for wholesalers and distributors. Buttermilk—in sizes anywhere from “a half-pint size all the way up to a truckload tanker,” says Shotts—is copacked for retail, bakeries and other large food manufacturers.

The ID Technology intermittent overprinter is offered in 2- or 5-in.-wide versions that can create text and bar codes at 300 dpi. Farmdale chose the 2-in. version with a black wax/resin ribbon, which enables the overprinter to produce a message that is 2 in. wide by 2 in. long with excellent scratch- and rub-resistance. Shotts says that the dairy selected the 2-in. model in order to save on ribbon costs, but nonetheless, he says that the resulting codes are “very readable.” He adds: “It’s very clear, more of a solid font than a dot matrix. The type is not very large, but it works very well for our needs.”

Keeping pace with the vf/f/s machine’s top-rated speed of 20 packs/min (depending on film type, package size and product viscosity), the intermittent TTO can print at speeds from 10 to 120 ft/min. At Farmdale, the overprinter is positioned on the pouching machine so that it adds the printed information onto unformed film rollstock as it feeds into the vf/f/s system.

Another requirement for the overprinter was its durability for use in the damp, washdown environment of the dairy. “Since we’re a dairy, we use a lot of water, so we needed equipment that was water-resistant,” Shotts says. To address this need, ID Technology installed the TTO within the vf/f/s machine so that the unit is protected behind Plexiglas(R) doors. Farmdale also chose the upgraded Unicontroller control and input device, designed for harsh environments.

Used to create and adjust the messages printed with the TTO, the Unicontroller is an industrial, Windows-based PC with a built-in, 32-MB Flashcard and Ethernet port. Operators program the overprinter by way of a 5.7-in. LCD touchscreen with an intuitive menu. Each job requires the operator to select an expiration date—either 30 or 60 days, according to the customer’s preference—and input a batch number. “After that, you push the enter button, and the overprinter starts running,” Shotts says.

He adds that the final feature necessary for the overprinter was low maintenance, which so far, the intermittent TTO has delivered. “You have to clean the printhead with a swab and alcohol every time you change the ribbon,” Shotts says. “We’ve only had to do it once so far. We have yet to have any other maintenance issues.” Although some of the larger-volume product previously packed in buckets has been moved into pouch packaging, Farmdale still offers its customers the option of using high-density polyethylene containers. “There are some advantages to the buckets versus the bags,” explains Shotts. “They can be resealed, and, with the bags, you have to work a little harder to get all of the sour cream out of the package.”

Farmdale has made an adjustment to its bucket packaging, however, to enhance its ease of use. In August, the dairy purchased six ink-jet printers, three of which are being used to print the expiration date, batch number and time onto the side of the sour-cream buckets; the balance are being used to apply codes to corrugated cases. Previously, Farmdale used wet-ink stamping machines to apply data onto the bottom of the buckets. Not only was the information inconvenient for the end user to access, but the stamping machines also produced inconsistent results. “We had to constantly monitor the printers,” says Shotts, “and sometimes we would have to get rid of product when the codes were not legible.”

Another problem was the time it took to change the printers over from one batch to the next—up to 15 minutes, Shotts says. This ate up a lot of time, considering the dairy typically runs up to 12 batches per day on its container lines.

Installed two at a time, beginning last August and ending in November, the new printers are Ci1000 noncontact, continuous ink-jet printers from Citronix, supplied by ID Technology. “We were looking for new small- and large-character coding systems and evaluated a few different brands,” says Shotts. “From our review, the Citronix ciSeries products provided the best fit for our applications. Not being fans of ink-jet, we needed something that was easy for our staff to understand and operate.”

The Citronix ciSeries technology allows Farmdale to meet both its small- and large-character coding requirements, eliminating the need for two different coding systems through the use of its PixelPlus™ feature. This feature provides a software selection of different drop sizes, throw distances and print heights.

” To our surprise,” says Shotts, “we were able to mount the printhead quite a few inches away from the product. This eliminated the potential for corrugated debris or sour cream to clog the printhead, which is what we had experienced with our former coding systems. The ciSeries technology is a robust technique.

” The user interface provides us with a very simple message input method and allows for quick changeovers. Minimal training was required to operate the graphical user interface, it is so simple to navigate. Looking towards the future, we opted for the ci1000, which has a fully integrated Ethernet communications port that allows for remote access and delivery of system warnings to our networked computers.”

The Citronix printers are capable of printing up to five lines of text, but Farmdale prints just one to keep consumables’ costs low, says Shotts. The dairy uses methyl ethyl ketone (MEK)-based ink that adheres well to the slick, HDPE surface of the pails.

Like the TTO, the new ink-jet printers are low-maintenance, only a change in the filters every six months.

Since installing the new TTO and its six new ink-jet printers, Shotts says that Farmdale is very pleased with the quality, reliability and ease of use of the equipment. However, he adds that it’s too soon to calculate the financial savings. “In terms of the overprinter, we’re still researching whether the economics have worked out the way we had anticipated they would when we replaced some containers with bags. We’re at a point where the price of resin is still changing all the time, so the financial impact of this packaging change still needs to be evaluated. But there definitely is a savings in using the bags.”

He adds that Farmdale has so far been able to run the ink-jet printers at the same cost as the previous, stamping method, but with a much greater level of legibility and reliability than formerly possible.

For more information -
* ID Technology Corp., 888/438-3242. www.idtechnology.com
* Citronix, 817/568-9800. www.citronix.com

As produce marketers nationwide find themselves facing new requirements calling for country-of-origin labeling (COOL), some are re-evaluating their approach to coding and marking.C.L. Henderson of Hendersonville, NC, is a good example. Until last spring, a pressure-sensitive labeler was used to apply pre-printed labels to the top of each shrink-wrapped tray of produce to indicate produce variety. On the bottom of the tray, workers applied a sticker carrying a best-if-used-by date.This approach was greatly improved with the installation of a Citronix ci1000 continuous ink-jet coding system from ID Technology.“It was the country-of-origin legislation that got us thinking this way,” says company president Alan Henderson. “The ink-jet system is capable of printing four lines of text, and one of those lines identifies country of origin. On another line, we ink jet the best-if-used-by date, so our operators no longer have to turn the trays over and apply that information by hand. Also ink-jet printed is a lot and ID code. ”Henderson is quick to point out that ink-jet coding on filmwrapped veggies is no walk in the park.

“As we compared the Citronix system with others we evaluated, we were impressed with how reliable it was,” says Henderson. “Remember, when you’re printing on film-wrapped produce, you’re talking about a pretty uneven surface. With this system we have, we’re throwing the ink one to two inches in some cases, and yet the resulting code is perfectly readable.”

Henderson also likes not having to inventory labels preprinted with produce variety and country of origin. This info is now stored in memory in the ci1000 and accessed at a touch screen as needed.

Ink-jet coding isn’t the only upgrade made recently at C.L. Henderson. The firm also has invested in decorated shrink film for the black expanded polystyrene trays it sends to the marketplace. Supplied by Robbie Manufacturing, the film is typically a 60-ga polyvinyl chloride printed flexo in four colors plus varnish. It’s applied by one of two Ulma shrink film applicators.

Operators manually load the EPS trays, which typically hold anywhere from three to a dozen pieces of produce. Trays move through the Ulma system at speeds as high as 60/min, and immediately afterwards they pass through an Auto Labe pressure-sensitive labeler that puts a bar-code label on each pack to make the pack scannable at the supermarket checkout counter. Next is the ci1000 ink-jet printer, which prints country of origin, lot identification, and sell-by date.

Henderson readily acknowledges that the tray-wrapped approach to produce marketing carries an upcharge compared to the more conventional method of simply shipping produce to retailers in bulk. But some of the cost is passed along, he says, and consumers don’t mind paying it.

“It’s partly a security thing,” says Henderson. “They like knowing that the cucumbers or green beans they buy have not been handled by countless fellow shoppers. They also appreciate the convenience. They don’t have to weigh or bag anything. It’s just grab and go.

“Basically,” he continues, “we’re trying to do in produce what the meat industry has succeeded in doing with meat. It’s a case-ready concept. It’s working, too. Supermarket chains love it, and consumers do, too.” Ink-jet coding isn’t the only upgrade made recently at C.L. Henderson. The firm also has invested in decorated shrink film for the black expanded polystyrene trays it sends to the marketplace. Supplied by Robbie Manufacturing, the film is typically a 60-ga polyvinyl chloride printed flexo in four colors plus varnish. It’s applied by one of two Ulma shrink film applicators.

Operators manually load the EPS trays, which typically hold anywhere from three to a dozen pieces of produce. Trays move through the Ulma system at speeds as high as 60/min, and immediately afterwards they pass through an Auto Labe pressure-sensitive labeler that puts a bar-code label on each pack to make the pack scannable at the supermarket checkout counter. Next is the ci1000 ink-jet printer, which prints country of origin, lot identification, and sell-by date.

Henderson readily acknowledges that the tray-wrapped approach to produce marketing carries an upcharge compared to the more conventional method of simply shipping produce to retailers in bulk. But some of the cost is passed along, he says, and consumers don’t mind paying it.

“It’s partly a security thing,” says Henderson. “They like knowing that the cucumbers or green beans they buy have not been handled by countless fellow shoppers. They also appreciate the convenience. They don’t have to weigh or bag anything. It’s just grab and go.

Published in ID Technology Newsletter – Volume 10 Issue 2, 2007. A leading Club Store chain recently called on the specialists at ID Technology to help them solve a particularly challenging product identification dilemma. The cases that they are marking are used for both shipping to the store and merchandising at the store level. The boxes have a barcode on the lower right hand corner of all four sides so that when they are loaded on the pallet, orientation doesn’t matter. When they get to the store, the pallet is put in place and the tops of the cases are removed at perforations to create a display, allowing customers to pull product directly from the case. All four barcodes are still visible on the case/box after the top is removed. The stores previous method of coding these cases was complicated and labor-intensive and it was slowing the stocking process and contributing to increased out-of-stocks. The specialists at ID Technology met with the customer, conducted a site visit, and then went to work on a solution. The IDT team came back with a recommendation to design and build a conveyor system equipped with four ci1000 inkjet printers. In the innovative solution, the cases are transported down the conveyor where they pass two (2) ci1000s mounted on either side of the conveyor. This allows the cases to be coded on opposing side panels. Next, the cases proceed further down the conveyor where a bump and turn wheel rotates the case 90 degrees where two (2) additional ci1000s are positioned to code the remaining panels. The cases now roll off the line coded on all four sides without the need for additional labor. As a result of this new upgrade, the chain has experienced faster throughput as well as reductions in labor costs and costly out-of-stocks.

ID Technology

www.idtechnology.com

Citronix introduces ciLink™ as a new standard feature with the ciSeries ci1000 printing systems. ciLink™ is an “industry first” Embedded Web Browser Interface.

ciLink™ features an embedded full web browser interface to allow complete, real time control locally or remotely. Anything accomplished at the system keyboard can be accomplished via the virtual web browser keyboard/interface. Systems can send e-mail notifications for routine maintenance and critical situations.

The feature is offered via an IP addressable Ethernet port. Systems can be integrated into your network allowing administrators to control a single system or a group of systems. Remote control is accomplished through an advanced set of operation commands with XML format for setting, retrieving and viewing messages, graphic images and system parameters.

“Remote control can be important to customers who cannot maintain close proximity to the working area of the systems, the use of ciLink™ provides the ability for managers to remotely monitor, control and receive remote system alerts,” said Michael Comer, Vice President, Engineering of Citronix.

Citronix introduces the ci2000 IP65 Continuous Ink Jet (CIJ) Printing System. The ci2000 is designed specifically for marking and coding applications that require the system to be used in extreme applications such as high dust or wash down production environments.

The ci2000 is housed in a rugged complete stainless steel enclosure and features positive air pressurization eliminating entry points for dust or water. A heating mechanism allows operation in extreme cold environments – 35ºf (5ºc) and channeled air flow technology ensure reliable operation in extreme hot environments – 113ºf (45ºc).

The ci2000 prints up to a 31 pixel image providing five lines of text, graphics and bar codes. Up to 1000 messages are entered via a true WYSIWYG message editor with drag and drop fields allowing unlimited message formats. Integrated hardware as standard, the ci2000 systems have Ethernet, multiple RS232, RS485, PS2, multiple programmable inputs and multiple programmable outputs including a solid-state relay. Information can be delivered to/from the systems simultaneously, allowing communication to remote systems, remote interfaces as well as database connectivity. The ciSeries ciLink™ Embedded Web Browser Interface is also included.ci2000 systems can print at speeds in excess of 1500 ft/minute (470M/minute). Multiple drop sizes are available through software selection. A 60, 65 or 75 micron drop is available allowing multiple print sizes and eliminating the need for dedicated coders for different coding requirements. Print heights are selectable between .06” (1.5mm) – .50” (12mm) providing the ability to print both small characters and large, bold characters.

The ci2000 range of systems are offered in a variety of configurations with several optional components to meet individual application demands. Specialty Inks and Systems are offered for engineered solutions to unique applications. Inks are available in multiple colors and solvent bases – including thermal sensitive color change inks, wet glass ink, caustic washable inks, steam-sterilisable inks, alcohol resistant inks, invisible / UV readable inks, food grade inks, white and yellow inks and many others to meet the demands of any marking requirement.

“The ci2000 ensures maximum uptime and long term reliability in extreme marking and coding applications,” said Chris Dubois, Product Manager of Citronix ciSeries products.

IMCL has launched a Nationwide Sales Promotion to reward Customers. The Promo starts on the 25th of November 2008 and ends in February 2009. The promo is to encourage companies to own their own coding machines at affordable prices.

IMCL Management, prior to the Promotion kick off date, parlied with the Press on the forth-coming event. The parley was held at IMCL head office in Lagos.

For over 20 years, CITRONIX has been a leading worldwide provider of product identification equipment, software, supplies and services for marking and coding in various manufacturing sectors and has it’s products distributed in over 40 countries.

IMCL offers a range of systems in a multitude of configurations to individual applications for applying identity marks, sell-by dates and lot-date codes.

The mission of IMCL is to become the 1st choice brand, the best and most profitable company in Africa for the supply, installation and servicing of reliable, high performance, end-to-end, coding, marking and intelligent manufacturing servicing solutions.

IMCL - Providing the best manufacturing marking and coding solutions!