Ichiban, UK - Largest UK sushi manufacturer
Ichiban UK (the UK’s largest Sushi Manufacturer) comply with retailer codes of practice thanks to automation and support from OAL.
Ichiban produces both own label and branded authentic sushi for major retailers in a growing UK market. At their single site in Suffolk they employ over 450 staff in a 24/7 operation, and last year alone they cooked around 1,200 tonnes of rice.
Challenge
Ichiban UK Ltd contacted OAL to investigate the implementation of a label verification and date code control system in response to the introduction of stricter rules, regulations and codes of practices set by retailers. Breaches of these codes of practice can result in substantial fines as well as loss of reputation.
The increasing consumption and popularity of sushi meant any installation needed to minimise downtime to maintain capacity.
“We chose the OAL system because it’s a tried and tested solution that provides the compliance we need. It’s easy to use and has helped us focus by accurately recording line stoppages and identifying areas for improvement.”
Solution
The OAL system was installed across five packing lines at Ichiban to ensure the correct label, date code and price has been applied to products. A touch screen terminal was installed on each line that linked to scanners, C Wrap labellers, Ice printers (Ice Thermal Transfer labeller), and Mettler Toledo checkweighers with a master database of products. A fifth mimic terminal was installed in the Low-Risk area for operators to carry out routine quality checks and to scan outer case label barcodes, ensuring products are packed in the correct case.
2D coding & scanning
2D barcoding and scanning allow Ichiban to scan products without using the EAN barcode which means all areas of packaging are traceable (to ensure the correct version of labels are used). This simple system reads every single code that passes through the scanner, compares it to the job inputted within the system by the line operator. If a mismatch error occurs the line completely stops and must be investigated and signed off by a manager.
Unlike 1D barcodes, 2D barcodes provide complete control over the version of packaging used. 2D barcodes are not under the control of the retailer, so can be adjusted when there are any minor changes to the packaging to ensure that old packaging is not used.
Promo labels
The OAL system provides assurance over the correct use of promo labels. By applying a 2D code to the front of the label or printing a 2D code onto the backing paper the label can be scanned. If the product does not require a promo label, the scanner will either detect the wrong barcode or will detect a consecutive no read and stop the line.
Results
Working with OAL has provided peace of mind to Ichiban by securing the label, date codes and price on their packaging. The system was installed quickly with minimal factory downtime.
Want to replicate Ichiban’s success? Contact us today to secure your factory.
At a glance
Customer since: 2015
Challenge
Risk of label and packaging errors.
Compliance with retailer codes of practice.
Solution
OAL Connected system installed across 5 packaging lines.
Support contract with audits to ensure retailer code of practice compliance.
Results
No product recalls since installation.
Easy compliance with retailer codes of practice.
