‘Cool’, New Automated Labelling Solution for Foodservice Packaging
A renowned foodservice provider from southern Germany needed to modernise two of its automated production lines but it needed the replacements to not only cater for existing mounts and options but, critically, also to reliably operate in a chilled processing environment.
The foodservice manufacturer produces high-quality small meat dishes, menu components, dips, sauces, and salad dressings for large-scale catering. Its customers include hotels, restaurants, quick-service chains, corporate canteens, bakeries, petrol stations, grocery retailers, and individual caterers.
Two Technical Challenges
The company uses a wide range of packaging types for food production but, for products packed in vacuum-formed pouches, flow packs, or trays, it has two dedicated production lines with integrated print-and-apply systems for top-side labelling.
The two existing print modules in its automatic labelling system had, however, become outdated, and needed replacing but there were two fundamental technical challenges: the manufacturer wanted to retain all its existing mounts and options and, secondly, it required the new modules to operate reliably in a chilled processing area. This was a crucial requirement that excluded many conventional print modules that typically need an ambient temperature of at least 5°C.
The foodservice provider turned to automatic identification and data capture (AIDC) systems specialist EZS Identtechnik, a long-standing distribution partner of TSC Auto ID. All teams collaborated and agreed that TSC’s powerful, flexible, and easy-to-integrate PEX-series print modules offered the best solution, not least because they could reliably perform at temperatures as low as –5°C.
(Sample image: AI-generated)
The PEX-2000 print module integrated into the packaging line ensures fast and reliable labelling of the filled food products.
Phased Integration
Implementation took place in two phases, each one scheduled over a production-free weekend. This allowed the foodservice provider to avoid downtime and, at the same time, test the new food-labelling solution on one line before moving on to the second.
The PEX modules automatically print on blank 100 mm x 100 mm labels and apply them to the primary packaging inline during the sealing process. Labels feature GS1-128 barcodes for shipping and distribution and, in some cases, other consumer-readable information like QR codes.
The company’s ERP system supplies all relevant product and logistics data, such as article number, name, ingredients, nutritional values, best-before date, and batch number.
About PEX-2000
TSC Auto ID’s PEX-2000 robust print modules are designed for long-term operation in demanding production environments where temperatures can be as low as –5°C. They are ideal for users in manufacturing — especially cook/chill food —, in transport and logistics, and in healthcare.
The 4-inch models reach print speeds of up to 457 mm/s (18 ips) with a maximum resolution of 600 dpi. The 6-inch versions print up to 356 mm/s (14 ips) with a maximum resolution of 300 dpi.
A DB15 or optional DB25 interface, GPIO emulations, and customisable firmware that supports a wide range of printer languages all ensure simple integration into existing systems.
The PEX-2000 modules are compact and can be mounted in any orientation within label applicators. Their functional design allows for expedient maintenance thanks to a rear housing section that is easily accessible and removable. Optional features include RFID encoding and ribbon-saving technology for reduced operating costs.
Increased Productivity and Quick ROI
Modernisation of the foodservice provider’s production lines using TSC Auto ID’s print modules has been deemed a major success, with a full return on investment (ROI) achieved in just a short time. Its throughput increased to as many as 3,500 labelled packages per hour, while print quality also improved significantly. The number of unreadable labels and QR codes were also drastically reduced, which is another important consideration for manufacturers who risk chargebacks or compliance fines for unreadable barcodes.
One thing the company was also keen to do was to be able to source all spare parts for these, and other devices such as its MH340 and MH341 industrial printers, from a single supplier. TSC Auto ID meets this need with fast delivery and service availability, helping to reliably prevent unplanned downtime. If complications arise, rapid remote diagnostics can be carried out using its TSC Console software tool.
(Sample image: AI-generated)
The label contains all essential product and logistics details, encoded in a GS1-128 barcode with supporting plain text information.
Future Expansion Already Planned
Thanks to the positive experience of replacing its print modules, the foodservice provider has now planned several follow-up projects, including integrating more of the PEX-2000 devices into other production lines and support for new product formats.
Thomas Rosenhammer, Territory Manager DACH at TSC Auto ID, says:
“Foodservice production demands high print speeds and excellent labelling quality across varying temperature conditions. Thanks to our close collaboration with our distribution partner, we once again received extremely positive feedback regarding technology, consulting, cost-efficiency, and service.”
Florian Stier, Managing Director of EZS Identtechnik, adds:
“The customer originally started with a single printer. Today, every printer used for label processing comes from TSC Auto ID.”
About TSC Auto ID
TSC Auto ID is a global leader in automatic identification and data capture (AIDC) technologies and thermal label printing, serving customers in more than 100 countries.
With a strong foundation in innovation, TSC Auto ID has expanded through strategic acquisitions. The 2024 addition of Bluebird Inc., a global leader in enterprise mobility, enhances its Auto ID ecosystem by integrating enterprise mobile computing, data capture, and label printing technologies and supplies. This strengthens its ability to deliver end-to-end automation in retail, logistics, manufacturing, and healthcare.
With a widespread global deployment, TSC Auto ID remains committed to engineering excellence and scalable innovation.
Learn more at www.tscprinters.com
LinkedIn: linkedin.com/showcase/tsc-auto-id-emea
About EZS Identtechnik
EZS Identtechnik is a leading provider of labelling and identification solutions in German-speaking regions. The Auto-ID specialist operates its own label and ribbon production and offers users comprehensive service from a single source.
More information: e-z-s.de