Metal Marking Gets 50% Efficiency Boost!

An International supplier within the aluminium extrusions industry upgraded from CIJ to DOD to achieve 50% improved efficiency, lower costs, and anticipated one-year ROI.

After experiencing consistent, production-halting performance issues with their existing CIJ printing solution, the company tackled their challenge by implementing VIAjet™ V-Series DOD Inkjet Printer with the MPERIA® automation platform from World Leading coding experts Matthews Marking Systems.

The company’s CIJ marking equipment regularly caused production line stoppage, putting their schedule at risk. Known for quality, expertise, and timeliness; failing to deliver on time to customers was unacceptable. The team replaced their existing printing solution with the VIAjet™ V-Series DOD inkjet printer with the MPERIA® automation platform.

Implementing this advanced system allowed the company to quickly achieve:

+ 50% greater line efficiency

+ Centralised control of print production

+ Substantially lower maintenance costs

+ Decreased ink costs

The new solution didn’t require any modifications to the existing production line and overall they anticipate seeing a full return on their investment within one year!

The Challenge

The company’s existing CIJ solution was not sustainable. They needed a dependable, industrial-grade marking solution that could:
+ Excel in the mill’s harsh environment,
+ Reliably perform with minimal maintenance, and
+ Produce a quality mark consistent with the brands reputation.

Their Plant Manager explained, “The system required a lot of ongoing maintenance, and regularly drove up our downtime costs.  There were times when we couldn’t fulfill customer orders because the printers were not working.  At times, the team was forced to move their one functional CIJ printer between facilities in order to maintain production flow.  We couldn’t afford to consistently delay customer orders due to printer malfunctions and those delays hurt our customer relationships and were damaging to our brand.”

The Solution

The VIAjet V-Series DOD inkjet printer with the MPERIA automation platform easily fulfilled their requirements, ensuring they could confidently meet operational goals while delivering customer satisfaction.

Outstanding Reliability, Durability, and Efficiency

The solution is durable enough to withstand even the most challenging industrial environments; provides optimal efficiency with the longest-life printheads in the industry (over 9 billion firings); and reliably prints crisp, clear marks with precise placement and timing. Routine cleaning and maintenance is greatly simplified with the flushing valve systems in the V-Series. An advanced printhead nozzle design, featuring exclusive micro-valve ink circulation technology, dramatically lowers ink consumption without compromising print quality. The combination of reliability, durability and efficiency allowed them to maintain maximum line productivity with minimal maintenance and almost no down time, driving their efficiency boost to a 50% gain.

Seamless Integration and Full Scalability

Designed to integrate easily with existing or new production lines, the VIAjet V-Series DOD inkjet printer with MPERIA controller is a complete solution that can function in a stand-alone or networked environment. The modular nature of the system makes it easy to grow from one V-Series on a line to multiple V-Series printers on additional lines, all driven by a single controller.

Centralised Control and Usability

MPERIA gives the company the capability to control marking and coding operations at any point on the production line from one central location. The single “one-touch” user interface controls all equipment—printers, barcode readers, vision systems, scales, and actuators—without the need for third-party software. MPERIA’s built-in message automation combined with the easy-to-use
control interface provides labour savings over the previous CIJ solution by reducing equipment touches and the training requirement for line operators and maintenance personnel.

Clear, Crisp Marks

The VIAjet V-Series DOD valve jet printheads produce incredible print quality on both porous and non-porous substrates including cardboard, wood, metal, rubber, and more. And they are able to achieve this high level of quality while also offering one of the fastest printing speeds in the industry at up to 780 feet per minute. The system is compatible with a wide variety of pigmented, dye-based, and fluorescent inks—including fast-dry versions—ensuring customers always have the exact ink needed for their mark.

The Results

“The VIAjet V-Series DOD inkjet printer has improved our efficiency by 50%.  In addition, the system is extremely robust and reliable, requires only minimal maintenance, and is much easier to operate. We finally feel confident that we can consistently deliver our customers’ orders on time,” explained their Plant Manager. In addition to these critical benefits, the company also reduced their
consumable costs thanks to the V-Series more efficient ink usage and lower-cost inks. They expect a full return on their investment within one year. By implementing the VIAjet V-Series DOD inkjet printer with MPERIA, the company has successfully ensured the end-to-end efficacy of their operation and eliminated issues that were negatively affecting customer relations and brand reputation.

ENDS

About the MPERIA® VIAjet V-Series Printing System

The MPERIA® VIAjet V-Series printing system represents the latest and most robust industrial ink-jet marking technology available, ensuring dependable long-term performance and reliability in the most demanding operating environments.  The system provides exceptional versatility and print quality for the application of variable product information and traceability codes, as well as barcodes, logos and graphics onto both porous and non-porous materials.

Typical applications include the coding & marking of Construction Products, Chemicals & Fertiliser, Industrial Packaging, Automotive Products, Foams, Plastics & Films, Paper & Pulp. The capability to operate in these sectors means that more basic applications are also suited to the V-series printer.

Click here for more on the VIAjet V-Series System

Click here to watch a video on MPERIA® and the benefits it could bring to your business.

For further information about MPERIA® and our range of printing technologies, please call Xact on 0151 479 3020 or email info@xactpack.co.uk

Case Coding for Worldwide Produce Brand = Major Productivity Gains and Cost Savings!

A worldwide leader in the procurement and marketing of fresh avocados and other fresh produce as well as the manufacturing and distribution of prepared avocado products and salsas were looking for a better system.

The company has been proudly serving produce wholesalers, retailers, and restaurants worldwide since 1924. Now, faced with excessive material expenses, downtime, and waste due to coding errors, and a critical lack of after-sales support, they turned to MPERIA to increase efficiency and decrease costs.

The company was using a standard Product Traceability Initiative (PTI) labelling solution that was costly in terms of operational expenses and risks.

By implementing MPERIA’s automated and centralised marking and coding solution with thermal inkjet (TIJ) print technology, they were able to achieve the following:

  • MAJOR COST REDUCTION – of material and maintenance
  • INCREASED EFFICIENCY – due to automation and centralised control
  • STRONGER SECURITY – via tiered user access
  • PEACE OF MIND – with excellent after-sales, one-on-one support
  • EXCELLENT ROI – solution will pay for itself in under a year

The Challenge
The company ships 12 million boxes of avocados annually. Their 53,000-square-foot facility contains 23 production lines and has served multiple purposes over the decades.

“Our previous marking solution was very expensive and completely lacking in after-sales support,” explained the Operations Manager at the plant. Repeated mislabelling issues resulted in production downtime, waste, and additional expenses to replace materials and product; a new solution was needed. “Data integration issues were not uncommon and—unfortunately—when they cropped up there was no one we could call to help us sort out technical problems.” In short, the traditional PTI labelling solution was costing the team, money and aggravation on an almost daily basis. They needed a more advanced solution that used technology to streamline the marking process; and they needed a reliable and responsive support team to help ensure everything was running smoothly.

The Solution
The MPERIA®️ platform with TIJ technology was the solution. Easy to implement, MPERIA is the only universal marking and coding automation platform that works with virtually any hardware or software. Its impressive flexibility makes it the ideal solution in a wide variety of environments and scenarios.

MPERIA®️ also allows for the centralisation of the marking process, simplifying initial setup and making it easy to scale the operation for growth. The system enables consolidated control over all marking and coding—whether from the factory floor or the production manager’s office—across primary, secondary, and tertiary lines.

The final solution included 22 L50 Printheads with thermal inkjet print technology and one MPERIA Standard Controller. This configuration allowed the company to put an individual printhead on each drop line—a creative idea that wasn’t possible with their old labelling solution. This innovation eliminated 100% of data integration errors as each drop line managed its own PTI coding information—no more camera system required for variable box sizes on the main conveyor line.

The Results

MAJOR REDUCTION IN COSTS: By transitioning from a labelling solution to direct print and eliminating the need for costly label materials, the company was able to instantly reduce overall costs to about one-fifth of what they had previously been paying. Also, because the cartridge-based system reduced maintenance issues to virtually nothing, they were able to eliminate what had previously been regular, ongoing maintenance costs.

INCREASED EFFICIENCY: The MPERIA®️system’s full automation combined with the elimination of labels meant line workers no longer needed to hand apply PTI codes. This allowed the team to reallocate resources to more profitable and productive tasks. It also takes the operations team much less time to manage changes and updates due to the centralised system.

STRONGER SECURITY: The MPERIA®️ system enables different levels of user access to guard against accidental setting changes that could create errors or otherwise jeopardize productivity.

EXCELLENT ROI: After assessing all the benefits of the new MPERIA®️system, estimates suggest that it will take less than a year for the MPERIA solution to pay for itself.

 

Click here to watch a video on MPERIA® and the benefits it could bring to your business.

For further information about MPERIA® and our range of printing technologies, please call Xact on 0151 479 3020 or email info@xactpack.co.uk

Wet Wipe Manufacturer Meets COVID-19 Challenges with Highly Scalable Coding Solutions

A large manufacturer of hygienic wet wipes achieved greater labelling efficiency with centralised control, reduced ink costs, and an anticipated quick-turn ROI.

Summary
Adaptability and agility are critical assets for any business, but today—with the additional challenges created by COVID-19—they are more important than ever. The global pandemic forced a fundamental shift in how companies do business, regardless of the industry they serve. Many had to adapt to a completely digital operation almost overnight while some were forced to develop new delivery models. And others faced an unprecedented surge in demand.

For this large manufacturer this meant an exponential increase in demand for their cleaning products as the coronavirus took hold all across the globe. To help respond to the situation, MPERIA® helped the company quickly replace their existing coding system to deliver:

• Centralised control to boost efficiency
• A 30% cost savings on ink
• An anticipated quick-turn ROI

The Challenge
The company which has been established for almost 25 years is a manufacturer of sanitising wipes that offers contract manufacturing to a variety of industries (foodservice, hospitality, cleaning, healthcare, and beauty) as well as their own premium and value wipes for the consumer market.

When COVID hit they pivoted to operating in the new norm while witnessing an astonishing increase in demand for one of their biggest product lines – the individual wipe packets included in many first-aid kits.
Unfortunately their existing coding system had several critical shortcomings. Most importantly, it could not scale to meet the surge in demand. Because the system was neither centralised nor capable of integration with the rest of the production systems, expanding their operations simply wasn’t feasible.

Additionally, the legacy system was truly inefficient. Its clunky, standalone user interface (UI) required floor operators to manually make changes across fifteen individual printers each time a code or date needed to be updated. Not only was this process incredibly time consuming, slowing production on a regular basis; it also increased the risk for potential coding errors.

The company knew a more efficient and modern coding solution must exist, one that would positively impact their bottom line while driving efficiency gains in operations and ink consumption.

The Solution
The MPERIA® controller with VIAjet™L-Series thermal inkjet (TIJ) printer offered everything they needed to modernize their production line for greater efficiency and cost effectiveness while also providing a seamless method to scale operations and meet growing demand.

ACCURACY, SPEED, AND HIGH RESOLUTION
They chose the L1 VIAjet printer, an ultra-compact, high-performance printhead, perfect for tight spaces and OEM integration. It’s an excellent solution for high-resolution codes up to 2mm (as well as larger codes and text up to 6mm), and ideal for the kind of high-speed commercial printing they do.
In addition to unmatched speed and quality, the VIAjet L1 also helps positively impact their bottom line with superior ink utilisation. Droplets of ink from the L1 printhead are smaller, translating to a yield advantage of nearly 30% over comparable HP cartridges. Also, because cartridge changeover is easy and happens less frequently, the company saves on routine maintenance costs and reduces downtime.

FLEXIBLE INTEGRATION OPTIONS AND SCALABILITY
Perhaps the most appealing feature of this solution is seamless scalability. The compact, low-profile system is fully networkable, allowing the company to connect all necessary components to a single MPERIA controller via Ethernet. True scalability enables easy expansion of their production capacity, adding printheads as needed.

EFFICIENT CENTRALISATION, USER-FRIENDLY INTERFACE, AND REMOTE ACCESS
Unlike their previous system, the MPERIA platform integrates easily with existing systems—virtually any ERP, MRP, or database. Because there’s no middleware or third-party hardware required, The company was able to manage the integration quickly and with very little effort.

Once integrated, the MPERIA platform centralises control of all the L-Series units so that making changes is painless. Instead of having to make the same change on multiple printers—slowing production and risking errors—the operator makes one change at the MPERIA controller, instantly updating all the printers on the line.

MPERIA® also gave the convenience of VNC (virtual network computing)—allowing remote management of the system from anywhere. This is especially relevant as production lines run five days per week, two shifts per day. Reliable, 24/7 remote access ensures consistently smooth operations and tremendous peace of mind.

The Results
The company was up and running with their new MPERIA solution in a couple of days. Their staff handled the installation without middleware or third-party hardware. The commissioning to set up the line, controller, and VNC also only took one day.

FAST, EASY SCALABILITY
The company initially implemented five VIAjet L1 Series printers at one location. They were so pleased with the initial results that they quickly installed five more printers in that facility and five additional printers at another location. Their plan is to expand this solution to their full production capacity, between 40 and 50 printers across two facilities. Flexible and scalable, the solution facilitates the easy addition of printers for them, ensuring they’re always able to meet a surge in demand.

CENTRALISED CONTROL
The MPERIA® platform gives efficient, centralized control of all the printers on their production line through a simple, user-friendly interface. In addition, it allows for remote access via VNC so that operators not only maintain social distance protocols while on the production floor, they can also see and manage what’s happening even when they aren’t on site.

COST SAVINGS AND QUICK-TURN ROI
Cost savings were apparent in three areas:
• Lower Ink Costs: Superior ink utilisation, as compared to HP cartridges, allows the company to generate 30% more printable quantity for the same cost.
• Lower Maintenance Costs: Easy-to-change cartridges and reduced frequency of changes helps them reduce expenses related to regular maintenance and upkeep.
• Greater Overall Efficiency: The centralised control, speed and accuracy of the printing process, and seamless system scalability all contribute to an overall increase in their production efficiency.
All of these cost savings combine to deliver an anticipated quick-turn ROI.


ENDS

Click here to watch a video on MPERIA® and the benefits it could bring to your business.

For further information about MPERIA® and our range of printing technologies, please call Xact on 0151 479 3020 or email info@xactpack.co.uk

Hot stuff! Coding & Marking Metal in Extreme High Temperatures.

Xact’s MPERIA® V-Series Printing System Provides Unrivalled Performance and Reliability….. Whatever the Conditions!

An international company manufacturing prime grade zinc alloys required in-line product coding and identification systems for hot metal ingots.  

Based on our experience within challenging production environments, our task was to provide a solution capable of withstanding extreme heat, moisture and vibration, as well as offering the facility to apply both human readable codes and multi-colour marking for the grade identification process.  Meeting all requirements (and more) we installed our MPERIA®  V-Series system managing multiple print heads across 3 separate areas of the production line. The V-Series technology is proven in extreme operating environments, so was the perfect solution for all marking processes at the plant.

Key to the decision-making process and placing their business with Xact was the unrivalled flexibility and mark quality the V-Series system provided the business despite the harsh operating environment.

Other advantages included;

  • The facility to manage all marking processes across multiple production lines from one user interface provides seamless control, helps to eliminate operator error, as well as reducing hardware at the line and associated investment costs
  • The future-proof modular design of the system provides the flexibility to add print heads, as well as managing in-line labelling systems, to fall in in line with future expansion at the plant
  • A wide range of ink types and colours, with the flexibility to add/change inks should the customers’ or their end-users requirements change in the future
  • Unrivalled throw distance (head to product) ensures the marking process and legibility of the codes and colour marking processes are unaffected by variances in the presentation of the ingots during the manufacturing process.
  • Our long-term expertise in the industrial sector gave added confidence in moving forward with Xact as it was essential the proposed solution could withstand the harsh operating environment of the manufacturing process, where amongst other conditions the heads are subjected to extreme temperatures and steam.

About the MPERIA® VIAjet V-Series Printing System

The MPERIA® VIAjet V-Series printing system represents the latest and most robust industrial ink-jet marking technology available, ensuring dependable long-term performance and reliability in the most demanding operating environments.  The system provides exceptional versatility and print quality for the application of variable product information and traceability codes, as well as barcodes, logos and graphics onto both porous and non-porous materials.

Typical applications include the coding & marking of Construction Products, Chemicals & Fertiliser, Industrial Packaging, Automotive Products, Foams, Plastics & Films, Paper & Pulp. The capability to operate in these sectors means that more basic applications are also suited to the V-series printer.

Click here for more on the VIAjet V-Series System

Click here to watch a video on MPERIA® and the benefits it could bring to your business.

For further information about MPERIA® and our range of printing technologies, please call Xact on 0151 479 3020 or email info@xactpack.co.uk

Join Us Live At The National Fruit Show 2020

Join us LIVE at the National Fruit Show next Thursday 22nd October! Come and chat to us – we’re talking all things Fresh Produce! Chat to us about our grading, packing and sorting solutions for all fresh produce. Visit our Virtual Booth! All you have to do is register here: https://nationalfruitshow.org.uk

Our Compostable Range

As a world leader in fruit and vegetable packaging, our partners Giró have developed a whole range of compostable products for maintaining a sustainable world.

This range is composed of clipped bags produced with net and labels, and thermalwelded bags produced with net and film. Both types are 100% compostable.

Furthermore, these compostable bags can be produced with their respective original machines: CA-9S and CA-10 clippers for compostable clipped bags and GirBagger and GirBagger Speed ​​Line welders for compostable thermalwelded bags.

For further information about our Net packing, please call Xact on 0151 479 3020 or email info@xactpack.co.uk

Net Packing & The Environment

Our net packs are amongst the most sustainable on the market.

The unique breathability and visibility of the net pack allow the produce to maintain all it’s natural features with the advantage of having an extremely lightweight pack. Our products are not only 100% recyclable, but they contain recycled material. We also offer compostable net solutions as part of our range.

Please click here for more information.

For further information about Net packing, please call Xact on 0151 479 3020 or email info@xactpack.co.uk

Concrete Info! Xact’s MPERIA® VIAjet V-Series Printing System…..The Most Trusted and Reliable Solution Across the Construction Industry

A leading UK manufacturer of concrete blocks required a robust and reliable in-line printing solution to meet their product identification, traceability and QA processes. The installation of our MPERIA® VIAjet V-Series printing system delivered on all key requirements…….and more!

Key to the decision-making process and placing their business with Xact was the unrivalled flexibility our MPERIA® system provided the business, such as the ability to manage the marking process across both block lines from a single interface with the facility to expand the system in the future.

Other factors influencing the decision-making process were;

  • The customer stipulated it was essential the proposed system could provide a large high quality print format to ensure clear visibility of the codes when blocks are stored in the yard
  • Our V-series systems are proven as the most industrial printing technology on the market, so the tough operating conditions of the plant (dust, vibration, variable operating temperatures etc) were no issue to long-term performance and reliability
  • Our years of expertise within the industrial sector, in-particular our knowledge of coding & marking construction products, provided added confidence for the customer to move forward with Xact.

About the MPERIA® VIAjet V-Series Printing System

The MPERIA ViaJet V series printing system represents the latest and most robust industrial ink-jet marking technology available, ensuring dependable long-term performance and reliability in the most demanding operating environments.  The system provides exceptional versatility and print quality for the application of variable product information and traceability codes, as well as barcodes, logos and graphics onto both porous and non-porous materials.   

Typical applications include the coding & marking of Construction Products, Chemicals & Fertiliser, Industrial Packaging, Automotive Products, Foams, Plastics & Films, Paper & Pulp. The capability to operate in these sectors means that more basic applications are also suited to the V-series printer.

Click here for more on the VIAjet V-Series System

Click here to watch a video on MPERIA® and the benefits it could bring to your business.

For further information about MPERIA® and our range of printing technologies, please call Xact on 0151 479 3020 or emailinfo@xactpack.co.uk

Automatic Handling Solutions

The demand for automating handling processes and being more efficient is becoming more prevalent. Using our automated packing systems and robotic automation will not only save you money by reducing operator costs, you will increase the quality, efficiency and consistency of your set up.

We provide everything from stand-alone robots to full automated systems embedded in existing production lines. Our solutions comprise ‘Robot Palletising’, ”Stacking’ and ‘High Speed Pick and Place’.

All our solutions have an integrated process control built with the latest robotic software, product and pallet handling conveyors. Covering all industries and providing full service and support, there has never been a better time to discover how our systems could work for you.

For more information click here:
https://xactpack.co.uk/automated-robotic-solutions/

Call today on 0151 479 3020 for more information.

COVID-19 Update

UPDATED 31/03/20

As the situation regarding COVID-19 unfolds and health and global travel restrictions are issued, we want to inform you we have taken steps to ensure continued support of your operation.  For now, we want to reassure you that our equipment supply chain and our sites remain operational.

As a supplier of products for fruit and vegetable packaging, we are an integral part of the supply chain of the food sector.  Some of our main clients are producers and packers of fruit and vegetables, who supply their packaged products, a basic necessity, to the main supermarkets and food stores throughout the United Kingdom.  These producers / packers need our products to be able to continue the packaging of products such as citrus, potatoes, onions and all kinds of fruit and vegetable products.  Therefore our products are included in the category of basic necessity, fundamental and essential to ensure the UK food supply chain does not suffer from shortages.

At company level we have taken the following steps:

  • Ensuring the safety of our employees by increasing the capacity to work from home
  • Increased sanitary-hygiene measures and stricter rules for company access
  • Rearranging our office structure so the skeleton staff are distanced
  • Reducing access to sites except in cases of emergency
  • Observing all travel bans and guidance provided by our government
  • Strongly encouraging virtual meetings via video conferencing to answer your requests for quotes, service calls and customer queries

Product Supply

Our ability to supply equipment, repair parts and ink is minimally impacted. We are actively monitoring our supply chain and have been working to ensure that our stock levels are reinforced to minimize potential interruptions. We have measures in place to reduce risk of illness and continue manufacturing as a supplier to life-sustaining businesses.

Service and Support

We have taken steps to protect our communities’ and employees’ health at all our facilities while ensuring that our customer service and technical support teams remain fully staffed and available to assist via our regular channels.

To prevent any costly downtime and anticipated increased lead times, we strongly recommend you review your stock and supply of critical spares. If you have any concerns, please contact us immediately at xact.orders@xactpack.co.uk

We will continue to monitor the situation very carefully and we will share more updates as the situation develops. In the meantime, you can address specific questions or concerns by contacting our Customer Service Team on 0151 479 3020 or by contacting your Sales Manager.

While the next few months will undoubtedly challenge our industry and the economy overall, we want to reassure you we will give you our continued support and we hope to be in position as much as is possible, to maintain business as usual.

We most of all wish you, your family and your employees well. 

The Xact Team