Automated Labeling Meets the Need for a Production Increase at Food Processor

Problem: A prominent manufacturer of hot dogs, lunch meat, and bologna wished to improve the production rate from their manufacturing line that generates these products. The demand for these products has increased and the company desired to improve production without increasing labor cost or negatively impacting any governmental regulations. The manufacturer desires to improve the current number of man hours that are expended for each 1,000 pounds of product manufactured. It is felt that the use of automated labeling will be able to meet the requirements of the company to increase production while decreasing the expense for labor. In the analysis of the production operation it was determined that the current manual labeling effort could be improved significantly by implementing label automation. Performing this type of production upgrade will typically eliminate the necessity of any personnel having to perform manual labeling. There is also an important need for labels and bar codes to be placed consistently on packaging at the same location each time. The correct bar codes must also be placed on the correct products each time. The retention of customers and the constraints of government regulations require that these production consistencies be accomplished.

Solution: The food processor is currently applying labels manually. It is determined by the solution provider that the labeling system should be placed at the end of the production line just prior to products being loaded on pallets. Placing the automated labeling in this location does allow the employees more time to pack products at the end of the line. These persons are no longer required to perform any labeling tasks, so they can spend more time being accurate with packing tasks.

A very important consistency that is brought to the food production line by automated labeling is the ability to place the label accurately at the same location with continued repeatability. With regulatory requirements at such a stringent level, the exact placement of product labels with high repeatability is required. Manual labeling could not always perform this task with a great deal of accuracy. Human error in the placement of labels can be caused by fatigue, or other human frailties. The other important feature that this automation brings to food packaging is the ability to consistently get the right label on the right products. Inaccuracy in manual labeling can lead to loss of customers and censure by regulators. The consistency of labeling is assured by the fact the device uses a bar code reader that verifies each label as it is placed on the product. This identity process eliminates the possibility of a label being incorrectly placed on the wrong product. The system constantly polices the actions that it takes. Automation helped this manufacturer to reduce incorrectly labeled products significantly

The particular automated labeling system selected by the company gives them the ability to be flexible in how they perform the labeling function. This system will allow them the flexibility of just applying labels or they can print the labels then apply them. The system is fully portable and easily set up. Having this system as part of the operation has reduced the average changeover time between production jobs, increasing the availability of products. This flexibility will let the processor expand their food product lines into other areas and still be able to label other products in the most optimum way. The speed of the labeling device is between 20 and 30 units, which does not slow down the production line. Labels are printed in 300 dpi at speeds up 12 per second. This system is controlled through spare input/output devices from a PLC. The labeling system is very compact in design and can be easily integrated with other automation devices that the manufacturer will want to use later. The system will separate, position, label, and discharge units very accurately.

A very attractive feature of this system is the fact that the solution provider of this well-designed system, can offer a custom design and delivery of this system in as short as 6 weeks. This will allow you to be able to respond to the demands of customers in a timely fashion, and stay within the bounds of government regulations. Continuous training in the use and set up of the system is being offered from the time you order it until your personnel are efficient in its running. The engineering staff will work with your operators of the equipment to assure you get their buy-in from the beginning so you will get the optimum performance of the equipment in your manufacturing. Having installed 100′s of these systems, the solution provider has the ability to design and install this system at any location at which you may currently operate or to which you may expand.

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