Automated Weighing and Labeling for the Meat Industry
在称重和标签中使用自动化已成为北美最成功的食品工业企业的基本实践. The meat industry is NO exception.
Meat Industry businesses have long become aware of the benefits of automated weighing and labeling for increasing profitability and minimizing compliance risks. 这些风险可能会导致可怕的情况,比如食品召回或消费者投诉.
What is an Automated Weighing & Labeling Solution?
Automated Weighing and Labeling Solutions are highly accurate, efficient, 以及简化的解决方案,提高了处理器在一致性下大批量生产的能力.
自动称重和标签解决方案通过消除产品称重和标签的手动方面来改善食品加工商的操作. This reduces human error and increases production throughput. 自动运动解决方案可以提供先进的功能,例如用于在称重前识别混合产品的入站产品识别. Automated weight and data capture, outbound label verification, reject management, and product sortation.
Problems of a Manual Weighing & Labeling Solution in the Meat Industry
An automated weighing and labeling Solution is a long-term investment a processor can make, that yields great returns throughout their production process. The typical places a processor sees ROI is:
- Increased throughput
- Ability to expand into higher-volume markets
- Reduced labeling errors
- Reduced human dependency
- Combining multiple lines into a single line
根据操作人员的不同,典型的手动称重线的平均吞吐量为每分钟10-12箱. An automated case weighing, and labeling line has an average throughput of 25 boxes per minute. The automated line has twice the throughput capabilities that a manual Solution has. While the automated weighing and labeling solution is costlier upfront than a manual system, the ROI is in the long-term volume of products generated. For example, 而不是付钱给操作员坐在每条生产线上给产品称重和贴上标签,同时付给他们40美元,000 a year, this can be invested into an automated weighing and label solution. In 3 years at that salary rate, the automated solution is paid for, and the human capital can be reallocated which in turn saves money.
As a processor begins to expand their operations, demand inevitably will overwhelm a manual system’s ability. 一些规模较小的加工商正在努力发展该组织,并向新市场拓展业务,他们的目标是为北美一些最大的食品分销商提供服务.
To be able to supply to these large-scale distributors, certain requirements need to be met by the supplier. One of the most important requirements, is the ability to produce in high volumes. A manual weigh and label process can only take a processor so far in terms of throughput. It would not be able to meet the demands of higher volume markets. 自动称重和标签解决方案能够始终如一地准确地满足体积输出目标.
Aside from being able to supply enough volume, large-scale distributors also have a rigid process for their label requirements. Labels need to be standardized GS1-28 barcoded labels, that are placed in the correct area of the box with very little variance deviation. 这是由于他们的策略是扫描托盘的相同区域,以便尽可能快速有效地进入库存. 自动称重和标签解决方案可以在同一地点一致准确地称重和标签产品,同时坚持标签应用的特定位置. 这向大型分销商验证了您拥有满足严格需求的解决方案,并且可以提供这些解决方案.
在实现自动称重和标签系统时,处理器的另一个主要投资回报率是减少对人力资本的依赖. A business can face human capital risks such as:
- Labour shortages due to external market events
- Employee retention
- Employee training
Processors can be faced with an evolving labour problem due to the COVID-19 pandemic, inflation, and other external problems. Employees could leave the facility and look for other work. 最近在食品加工行业发生的事件表明,雇主提供激励性签约奖金来吸引新人才. However, incentive programs have met minimal success. 那些成功抵御外部劳动力压力的食品加工商也遇到了留住员工的问题. This leaves a processor with a constant issue of hiring, training, and dealing with turnover rates. 自动称重和标签解决方案可以将人力资本从称重和标签过程重新分配到工厂内的其他区域, while the automated solution can now handle those functions.
自动称重和贴标解决方案的另一个主要优点是将多条线合并为一条线. A typical processor will have multiple lines based on various products being produced. Instead of having two or three stand-alone manual lines, a processor can save real estate by joining lines. This will also reduce the number of operators for their packaging operation.
What are the key components of an automated food labeling solution?
Automated Weighing and Labeling Solutions are multi-component solutions. These include:
- Print and Apply Solutions
- Conveyor Scales
- Inbound & Outbound Scanning
- Box Indexer
- Sortation
Print and Apply Systems
打印和应用解决方案是为各种环境设计的,如潮湿环境, dry, humid, washdown intensive, etc. Some of the different component structures for a Print and Apply Solution are:
- Pneumatic Powered
- Electric Powered
Pneumatic powered applicators are typically used in a stable environment, that is not wet, harsh, humid, etc. Designed to meet the demanding needs of manufacturing, warehouse, distribution, fulfillment, or third-party logistics (3PL) environments. 利用零浪费气动,以便一致和准确地将标签应用于传送线上的动态机箱. Pneumatic applicators are a great starting point for most processors to meet volume, speed, and accuracy requirements. However, in wet, washdown, or harsh environments, pneumatic applicators cannot operate as efficiently. This is because a cold environment impedes the compressed air flow, causing low pressure and reduces the print and apply Solutions’ effectiveness. This is generally where most processors will look to electric print and apply Solutions.
Electric print and apply Solutions are all-electric label automation Solutions that are durable, reliable, and a consistent option for exceptional print and apply performance. Electric applicators are a great consideration for a processor whose operations are fast-moving, high volume, and have harsher environments. While electric print and apply Solutions are typically costlier than pneumatic, they come with a slew of benefits. For example, the system’s adaptive applicator automatically adjusts to carton heights while items are in motion, delivering exceptional capabilities to support complex supply chain and material handling operations. 对于有足够资金进行长期投资的处理器来说,电子打印和应用解决方案是一个绝佳的选择,这将推动底线. Print and apply Solutions are one component of an automated weighing and labeling solution. They work in tandem with conveyor scale Solutions.
Conveyor Scales
Conveyor scales offer incredible in-motion weighing accuracy with high-speed capabilities. The scale is fitted with a smooth belt-driven design to minimize vibrations during weighing. 他们可以设计,以确保规模适合您现有的过程,并满足您的确切需求. Constructed for harsh, 冲洗环境,当处理器在其设施中向自动化过程移动以适应更高的容量时,它们是一个很好的补充.
Conveyor scales are typically fitted between an infeed conveyor and where the product is flowing, and an outbound conveyor towards a palletizing section. A conveyor scale works in tandem with a print and apply system. Photo eyes are placed before and after the conveyor scale which triggers the weighing process. Once the box is weighed, 另一个照片眼触发打印和应用解决方案,在称重后自动标记产品. Another addition a processor can make to a conveyor scale solution, is a box indexer.
Box Indexers
Box indexers are a great addition to an existing conveyor Solution that can be added. The box indexer ensures that there is consistent box spacing. It enables down-line printers, checkweighers, conveyor scales, and scanners to function within specifications that a processor can determine. A box indexer prevents an overflow of products that can cause production downtime.
Most processors typically have a multitude of different products that they are producing and selling. Scanning is another aspect of an automated weighing and labeling system, that further enhances the solution through product verification and tracking. Inbound scanning determines the different products traveling down the conveyor. This allows the software application to select the right label format for the product. Outbound scanning is a verification that the product being weighed has the correct label on it. 如果产品不符合设定的参数或标签不正确,也可以在溶液中添加导流剂, so a box can be reworked correctly. 入站和出站扫描还提供了产品在整个生产过程中实时位置的清晰图像.
With various products, a processor can have multiple products on a single conveyor line. 分拣是另一个可以增加,以提高自动称重和标签解决方案. A processor may have various sortation lines for different products, which then have their own respective palletizing area. 拥有一个排序解决方案是一个主要的好处,因为它减少了在一条生产线上对多个产品进行排序的需要,并提高了整个生产线的效率和吞吐量.
自动称重和标签系统的主要总体好处是最小的人机交互. 操作员仍然需要在出现错误时在场,例如产品被拒绝,需要他们手动重新启动生产线. However, 人力资本可以从称重和标签过程重新分配到工厂内的其他领域.
How can Carlisle Technology help?
Over the past 30+ years, 拉菲2在线登录注册赢得了坚实的声誉,在北美提供最好的综合案例称重和标签解决方案. 拉菲2在线登录注册公司的自动箱子称重和标签解决方案将业界最强大的硬件解决方案与我们的可配置拉菲2注册登录集成在一起. 我们与最好的制造商合作,提供最好的品种高精度动态纸箱秤, product indexers, infeed conveyors, and print and apply Solutions.
If you have any questions on food weighing and labeling solutions, we would love to hear from you. 给我们一个电话,我们的专家可以帮助您选择正确的称重和标签解决方案,并指导您完成实施过程.
Written by: Joe O’Keefe, Account Manager – Carlisle Technology
Sign Up for Our Newsletter!
Receive updates on products, customer stories, and giveaways!
By submitting this form, you are consenting to receive marketing emails from: . You can revoke your consent to receive emails at any time by using the SafeUnsubscribe® link, found at the bottom of every email. Emails are serviced by Constant Contact