Integrated Labeling Sealer Dessert Packaging

Ever wonder why there is a hole in the center of the bagel? For Sara Lee Pastry Group (SLBG), the real problem is not a hole in the face of these breakfast dishes, but how to find innovative ways to package desserts containing sugar powder and chocolate more effectively. Today, SLBG's mini bagels can be contained in a spacious container made of crystal-clear polyester vinyl with a two-pound volume, and SLBG's traditional packaging methods are replaced with advanced labeling and sealing techniques. This attractive container is very attractive to customers and consumers. It guarantees the product's quality and safety, and effectively seals the fresh-keeping bread dough without shortening the shelf life of the product. However, like any gems, the packaging of this dessert also needs to be polished and polished to meet market challenges.

Meet new challenges

Founded in 1926 by the Gardner family, SLBG is headquartered in Madison, Wisconsin. This commercial baking company produces desserts, breads, and cakes in addition to mini bagels. “A major retailer came to us and asked to develop a large container to package the doughnuts according to their specifications and needs.” Plant Manager Steve Vial explained, “Before this packaging was developed, the market was really not that big The containers are for mini bagels. We modified our packaging. We modified our packaging process and arranged internal demonstration shifts to handle container sealing processes using disposable tape."

SLGB contacted Custom Label Source's Fastrak division, which is the sole distributor of Loveshaw, a manufacturer specializing in the manufacture of automated labeling equipment and packaging, sealing and printing systems. Vial said that the goal of using a new transparent box-like packaging container includes improving the product's promotional capabilities, producing aesthetic visual effects, enhancing product visibility and enhancing the protection of fragile doughnuts. To make it easy to display, also ensure that the doughnuts are fresh (shelf life is 14 days). For SLBG, improving production efficiency is also a major factor. Vial pointed out that in today's fiercely competitive, high-tech business environment, more and more business models and internal operations - including commercialized baking environments - are market-driven. When a customer who influences the sales of a product presents a different packaging requirement, the baking manufacturer must listen carefully.

He went on to say: “This is just like the other commodities that customers and retailers need, just like low-calorie foods. We caught up with the first wave so we are now leading the market in similar products.”

A new 2-lb.-volume doughnut box thermoformed by Stone Plastics, 4 inches deep, 5 inches wide, and approximately 10.5 inches long. A more noteworthy area on the container is a preprinted pressure-sensitive label affixed to a snap cap made of transparent PET material, 5 inches in diameter.

Vial said that the container can hold up to 64 baskets in surplus, making it very suitable for the specifications of the affiliate store, and the recessed lid also makes it easy to stack. PET materials are loved for their transparency, durability, and coordination with the product.

However, there is a challenge in the SLBG's bag-packing project. “The real challenge is not only to stick labels, but also how to seal large boxes with adhesive tape without damaging the inside of the doughnuts, and we have to be consistent with our internal production system.” Vial said, “Meeting the needs of the market and customers is We are at the heart of our business, so we're up and coming in. But we need some help from outside."

The company started by manually labeling and sealing each package to ensure that the products were handled properly and that the package maintained a good appearance both in transportation and in the market. However, this has become labor-intensive slow production. Since the production time is critical in the baking industry and the baked products are not durable, slow production or increased manual labor is not a good way to produce doughnuts.

Vial added: "Automatic labeling of containers is a natural process, so it is not a problem. The problem is how to automate the rapid sealing of tape. We need to control the production line at a reasonable speed - we use the assembly line to produce doughnuts - But we realize we can't stop and use our hand to quickly label our products.”

Soon, SLBG contacted Norm Ringler of Fastrak. Ringler explained: “We used to work with SLBG before, so we are familiar with their operations.” Then SLBG and Fastrak discussed their needs from the perspective of operations and customers. The solution was to modify Loveshaw's Little David LS600 ps labeler and integrate it with the Little David LD3SB's tape sealer, which Loveshaw now calls SP3/FA.

Ringler recalled, “We contacted Loveshaw immediately after we had identified all of Sara Lee's goals.” A team consisting of staff from Loveshaw and Fastrak formed a team with details and logistics provided by SLBG. Within eight weeks, the team united the LS600's labeling machine with the LDSB's tape sealing machine and installed them as a piece of equipment in Wisconsin's baking plant.

We have faced difficulties, but eventually found a perfect one-stop solution.

When the doughnut rolls along the conveyor belt, the operator on the packaging line loads them into the plastic PET container and immediately puts the lid on. Next, the container enters a modular labeler and is affixed with a round label that is torn off from the automatic feeder. The pressure-sensitive label must be affixed to the center of the large lid at a rate of 20 per minute. This is not an easy task given that the soft packaging cannot be affected by the sticking pressure and the doughnut cannot be damaged. This brings some challenges. Pat McGrath, a district representative for Loveshaw, admitted: “It's not an easy task to gently place a pressure-sensitive label on such a thin cover, but also to avoid breaking the product or packaging.” The Tamp method proved to work well. The pneumatic tape machine of the sealer is activated by the sensor, which ensures that the system can accurately place the tape on the container without much support and it will not damage or contaminate the container and the doughnut inside.

SP3/FA gives production surprises

Like any kind of automation system, some accidents occurred during the debugging after installation. During the baking and manufacturing process of the powdered bagel production line, the powdered sugar sometimes becomes dust, diffuses in the air in the production line area or accumulates on the packaging equipment. A few weeks after the new PET container was put into production, the powdered icing sugar reacted with the sealer's tape box and began to stick to the tape and often broke it.

The powdered sugar also enters the supply roll for the support tape and cuts the tape into shafts and sleeves for the appropriate length of the tape dispenser.

Fastrak and Loveshaw took immediate action to replace the tape during the warranty period and to check for damage to the shaft and sleeve and the extent to which it was affected by the powdered sugar. Loveshaw modified the sleeves and seals and sent the newly modified tape dispenser to SLBG within a few working days. With the help of the SLBG maintenance department, the refurbished system was closely monitored.

Soon after, the bakehouse doubled the output of the bread dough product, which also reduced the labor force and improved the efficiency. “We must always look at the entire process, especially considering the soft PET containers and daily doughnut production,” Vial pointed out. “The earlier delays caused by artificial sticky labels and seals have completely disappeared.”

In production, the packaged goods are sent to the SP3/FA labelling/sealing machine by the power belt of the bakehouse, and are separated one by one at an appropriate spacing. A side conveyor conveyor was passed through a pneumatic C-belt machine and the tape was glued to the lid to make sure it was bonded to 2.25 to 2.5 inches of tape perpendicular to the front and rear ends of the container. The tightly sealed lid keeps the tall containers stable during shipping and storage.

Since the start of the project, SLBG has installed three of the Loveshaw SP3/FA labelling/sealing machines that are specifically manufactured and modified at its Wisconsin plant. The system also installed casters so that they can be pulled out of service at any time on the production line.

“Our maintenance team designed a system that allows us to use Wheels to get the Loveshaw machines in and out of the production line on demand,” concludes Vial. "We have emerged from the predicament and started looking for solutions. We finally found a turnkey system that works flawlessly."

Until today, the machine has been working very well and only requires routine maintenance. Vial admired: "We are very satisfied with this packaging equipment. On average, we produce more than 30,000 two pounds of product each week with about 60 hours of work. The system is running flawlessly."

With the custom packaging equipment in place and near-perfect work, SLBG can now focus on what it does best - baking doughnuts, desserts, breads, and cakes. In addition to being at a specific membership store, the new two-pound bagel products are also available at direct outlets in many locations in the Midwest. The concerted efforts of Loveshaw, Fastrak and SLBG proved to be a successful combination to meet the needs of retailers and consumers. â–  Author: Senior Editor: Lauren R. Hartman (Packaging Digest China)