Packaging
Joker in the Pack: Domino Coding and Marking Technology Improves Efficiency and Reliabilty for Eckes-Granini
Tuesday 21. April 2009 - Frances undisputed leader in the fruit juice market, Eckes-Granini, is enjoying major improvements in the speed and reliability of its coding and marking operations on leading brands including Joker, Réa and granini, thanks to the installation of product to pallet coding technology from Domino.
The impressive production capacity at Eckes-Granini is reflected in statistics from the companys 50,000m2 facility in Macon: over 500,000 bottles and cartons are produced daily, amounting to a staggering annual output of 300 million litres of fruit beverages.
As with any beverage manufacturer, pivotal to Eckes-Graninis production operations is the need for robust, high-speed, high-quality coding and marking solutions to effectively apply variable data such as bar codes and traceability codes.
Two years ago, having established a requirement for improved performance and reliability from its coding and marking equipment, Eckes-Granini decided not to continue its fifteen year association with its existing supplier. Instead, Operations Manager, Thierry David, selected to invest in Domino technology, and since that time, has embarked upon a rapid installation programme that spans Dominos primary, secondary and tertiary coding solutions portfolio.
“We had become unimpressed with the rising costs of our incumbent provider, which together with increasingly sub-standard equipment quality, presented us with a few problems,” explains David. “Since selecting Domino as our exclusive supplier, we have noticed a significant improvement in the speed and reliability of our coding and marking equipment, which has enhanced our overall manufacturing operations immensely.”
In total, Eckes-Granini has four production lines in Macon; these comprise two PET blowmoulding lines – one Serac and one SIG – each of which fills around 200,000 bottles daily. Two Domino A200 small character continuous inkjet (CIJ) printers are now installed on each line to apply best before date and timestamp information. Three more A200s operate on the companys Tetra Pak line, which sees the same data applied to two litre gable-top cartons, while an eighth A200 is positioned on its Ovaline line to code the companys distinctive oval Joker juice cartons. At the secondary level, three Domino C3000+ outer case coders cover the production lines needs for high-definition printing directly onto cardboard storage boxes.
In addition, Eckes-Granini has installed seven of Dominos flexible and reliable M-Series Print and Apply Labellers to fulfil the companys pallet labelling needs. First, M100 direct thermal label printers apply barcode labels to multiple products once stacked and stretch-wrapped. When palletised, an A5-sized barcode label is directly printed and applied onto the wrapped pallets using Dominos M200P.
“The barcodes that are applied by the M-Series labellers are re-read by a detection head which interfaces with our logistics system. This is vital as it ensures we have full traceability through the supply chain,” says David.
Having one solutions supplier to serve the companys entire coding and marking needs was, for David, a key prerequisite. “From a time and efficiency aspect, the fact that I only need to speak to one person from one supplier is a real bonus,” he says. “This also increases our equipment flexibility and compatibility; we use the same ink and can minimise spare parts stock, thanks to cross-compatibility between coding units.”
According to David, the need for constant machine uptime and enhanced production line efficiency goes hand-in-hand with having the right equipment. “With our previous system, regular line stops for cleaning were a fact of life, with a resulting impact on productivity. Upon ink refills, our operators had to unscrew, empty and refill the system manually, which was both irksome and messy. With Dominos system, there is no contact with the ink – they simply clip in the cartridge and the machine is running immediately.”
As regards production speeds, David is equally impressed with the performance of Dominos user-friendly A-Series CIJ printers. “Our fastest lines are our two PET lines, which typically run at round 40-60m per hour and print 10,000 bottles during that time,” he explains. “Our A200s can handle 40,000 bottles an hour, so Ive no worries at all about their capability.”
Eckes-Granini is provided further peace of mind, having signed up for Dominos TotalCare plus Premium contract to cover its finishing line printers. This ensures that, should they need it, immediate access to Dominos industry renowned expertise and back-up support is readily accessible.
“TotalCare plus basically gives me a hotline to a Domino engineer,” explains David. “On the odd occasion that we have called them, they have been particularly thorough by undertaking preventative maintenance across the whole system.”
Two years on and with Eckes-Graninis total coding, marking and traceability needs taken care of, David has no regrets about replacing the companys long-standing contract with its former supplier. “Given the scale of our operations, we cannot afford to be complacent at any stage of our production process; doing so could otherwise lead to unthinkable consequences.
“Dominos team impressed me from the outset with their responsiveness and innovative technology proposition. Our production, as well as our position in the marketplace, is all the better for having made the decision to partner with them,” he concludes.