Wealmoor, UK - Improving Quality with Automation
Wealmoor has built a reputation for specialty fruit and vegetables, supplying high-volume, high-quality produce every week. Across their UK factories, they have automated their date coding and packaging processes with the OAL Connected system including Autocoding and APRIL Eye functionality. Going digital has enabled them to eliminate product packaging and quality issues and significantly reduce food waste.
Wealmoor has built a reputation for specialty fruit and vegetables, supplying high-volume, high-quality produce every week. Across their UK factories, they have automated their date coding and packaging processes with the OAL Connected system. Going digital has enabled them to eliminate product packaging and quality issues and significantly reduce food waste.
Background
Wealmoor is an established, family-owned business specialising in the growing, packing and marketing of subtropical fresh fruits and vegetables from all over the world. They also produce homegrown seasonal vegetables and herbs.
In 2020, the company began investigating ways to help reduce food waste, product recalls, and complaints by transforming their operations. In particular, product packaging and quality errors in the packhouse were identified as a key area of improvement.
Challenge
Like many fresh produce companies, Wealmoor’s packaging processes were manual and paper-based. Use by dates were being manually adjusted on the printer by an operative checking against a printed reference document, which on occasion resulted in date errors. Shelf life could also be calculated for longer than intended. Possibility of these errors could result in product recalls, damaging company reputation and customer confidence whilst also being very costly.
Furthermore, batch processing was difficult as many products had to comply with a range of different customer requirements. For example, one product had over 40 different SKUs, making it difficult under a multi-tasked, constant pressure environment for line leaders to determine if a product was in the wrong packaging easily. As a result, both products and energy could be wasted.
Finally, Wealmoor’s offline print room was using an end-of-life label design software called Dataguard, which needed to be replaced with an integrated solution for label management.
Solution
Wealmoor chose to implement the OAL Connected system with Autocoding, Paperless and APRIL Eye functionality within their UK factories. These systems allowed them to both digitalise and integrate their systems to reduce manual errors. The controlled and centralised technical database that OAL Connected provided removed a large amount of paperwork whilst also ensuring that customer specifications were correctly adhered to every time.
By implementing the Autocoding and APRIL Eye modules, operational quality control was significantly enhanced. The system ensured that date codes and shelf life were correct and accurate, preventing production errors, rework and product wastage. Structured quality control testing regimes were put in place, which could be tailored to different customer specifications. In addition, a system was introduced that would check for errors and automatically stop the line before production was significantly affected. This made packaging, film, and ingredient errors much less likely.
The OAL solution automated online and offline label printing, replacing the existing Dataguard & Vector label design software with Clarisoft. For operators, this resulted in a streamlined user experience as they use one system for both online and offline printing.
“The introduction of automated systems from OAL has completely changed our operations. Since its installation, we’ve been able to streamline our processes and prevent errors before they caused further issues, protecting our reputation, enhancing trust and confidence. We’ve also seen the significant opportunity in increasing efficiency and operational effectiveness.”
Key results
The new system has prevented human error such as incorrect film application, packaging issues, and incorrect dates and barcodes in the packhouse. As a result, operational downtime has been minimised and wastage and product recalls have been prevented. In turn, this has helped the company protect their reputation and drive sustainability.
A further benefit of digitalising their systems is that is has allowed Wealmoor to upskill their staff and improve employee engagement and retention.
Transitioning to an integrated, automated system doesn’t have to be difficult – speak to one of our team for expert advice and guidance.
At a glance
Customer since: 2021
Challenge
Automate and digitalise existing paper-based processes
Reduce food and energy waste caused by date and coding errors
Improve quality control and correct labelling
Solution
OAL Connected with Autocoding, Paperless and APRIL Eye functionality.
Implemented a controlled, centralised, digital technical database.
Introduced structured quality control testing regimes tailored to customer specifications.
Results
100% compliance with customer requirements.
Reduced energy and food waste through fewer production errors.
Improved quality control through automated system.
Life Health Foods, UK - Label and date code verification
Pioneer Foods produce a range of breakfasts cereals for many of the UK’s leading retailers and brands. OAL helps protect their 280 SKUs from packaging errors with automation.
Life Health Foods (formerly Pioneer Foods) produce a range of breakfasts cereals for many of the UK’s leading retailers and brands. They manufacture around 280 SKUs from over 300 raw materials including numerous allergens.
“Without a doubt I would recommend OAL to other manufacturers. It gives us the sense we are doing everything we possibly can to mitigate risk. And yes sometimes there’s mistakes but this system is the fail-safe and it makes sure those mistakes don’t go outside of your business.”
Challenge
Like many food businesses, the site relied on paperwork and manual human inspection to verify the right date code and packaging is applied to their products.
Life Health Foods wanted a failsafe system to stop the risk of packaging errors entering the supply chain.
Solution
We installed our OAL Connected system across 5 packaging lines at Pioneer Foods. The solution was “a breath of fresh air” to Life Health Foods, scanning every date code before it leaves the facility and checking against the pre-programmed date to avoid errors and prevent product recalls.
“Planning, installation, training, support has been very, very easy.”
Fancy a breath of fresh air? Let us safeguard your packaging line today.
At a glance
Customer since: 2017
Challenge
Risk of packaging error from human errors
Reliance on paper-based manual checks.
Multiple retailer customers with over 280 SKUs and allergen risks.
Solution
OAL Connected installed across 5 packing lines
24/7 support contract with audits to ensure retailer code of practice compliance.
Results
Zero packaging errors and improved customer relations.
Removal of manual systems and paper-work
Blue Earth Foods, UK - Label and date code verification
Blue Earth is a major supplier of chilled seafood products to supermarkets throughout the United Kingdom and Europe. When choosing an automated solution, a key requirement was to avoid downtime during installation and OAL Connected rose to the challenge.
Blue Earth Foods is a major supplier of chilled seafood products to retail supermarkets throughout the United Kingdom and Europe. OAL has worked with the rapidly expanding business since 2009 providing autocoding across their packaging lines.
Challenge
Like the whole of the food industry, Blue Earth foods were facing increasing pressure from retailers to guarantee that all packaging and date coding was correct.
Correct packaging and data coding prevent product recalls and withdrawals that not only jeopardise their customer relationships but also have high fines associated with them. A robust and expandable system was needed to eliminate these risks whilst minimising any disruption to food production.
The key elements of the data code and labelling challenge at Blue Earth Foods were as follows:
Similar packaging because many of the products fell within the same ranges
High variance in date codes because of short life on products between production runs
Printed top webs with no barcode identification on them could be incorrectly used on another product
Packaging format, thermoformed trays, printed top web & base label
Blue Earth achieved date code and label verification with minimum disruption to its manufacturing operations. Since rolling the system over further lines, there has been 100% data and label verification with no associated product withdrawals or recalls.
“From a technical point of view, OAL understood not only our needs but our customers’ needs as well. This was an invaluable asset that facilitates joint decision making. The system is easy to use and gives you peace of mind and reassurance that the correct dates and packaging are on the product. ”
Solution
Blue Earth foods chose OAL because they understood the tried and tested Autocoding system being offered meant that they could achieve correct date code and packaging verification with minimal disruption to production.
For Blue Earth Foods convenience, OAL deployed the Autocoding system in a staggered approach. Initially, two lines, a central product database and supervisory software were installed. This minimised interruption to production and gave Blue Earth flexibility to roll out the system to remaining lines when required.
For the first phase, 2D barcodes were added to the film & labels. This gave full version control over the packaging to product checks, even when a standard 1D barcode was not printed. Omni-directional scanners were used to check the 2D codes on film and 1D codes on labels which meant that all potential challenges highlighted were solved.
“The installation team were easy to get on with and very obliging. They already know the food industry and its standards and as such managed the installation accordingly to eliminate product risk and line downtime”
Want to automate your label & date code verification? Get started with OAL Connected!
At a glance
Customer since: 2009
Challenge
Risk of packaging error from human errors
Reliance on paper-based manual checks.
Multiple retailer customers with over 280 SKUs and allergen risks.
Solution
OAL Connected installed across 5 packing lines
24/7 support contract with audits to ensure retailer code of practice compliance.
Results
Zero packaging errors and improved customer relations.
Removal of manual systems and paper-work
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 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.
Heinz Secure Infant Formula Packaging Integrity with OAL System
Heinz secures infant formula packaging integrity with OAL automation system scanning spinning cans at 97ppm.
100% read rates on spinning cans at a rate of 97 per minute to secure packaging integrity of baby formula for Heinz.
Customer
At the HJ Heinz factory in Cumbria, UK, baby milk powder is manufactured and packaged ready for distribution overseas. Due to the sensitive nature of the products, accurate barcode reading is essential to ensure the correct products are identified and shipped to the correct customer.
Challenge
The site was using a label verification system from another supplier where one element could only read ladder barcodes. Although a separate system was created to read the picket fence barcodes, the readers could not cope with the 97 cans per minute high-speed production. Heinz were keen to upgrade to a more reliable system which could achieve 100% read rates, eliminating any risk of packaging errors.
“Heinz chose the OAL Autocoding system because they were the only suppliers we reviewed to offer 100% read rates on products. The integrated quality checks on the Autocoding system and ability to offer 24-hour support have added significant value to the business.”
Solution
OAL installed their Autocoding system using six Cognex DataMan 302X readers, enabling at least two of the readers to read the code on the can as it rotated through 360 degrees. Importantly the system was able to handle the convex structure and reflective surface of the large cans. If incorrect barcodes or ‘no reads’ are detected, alarm beacons and display screens alert the operators who will stop the line and clear the defective product to ensure no incorrect product continues into the packaging area.
Read rates are reported as part of the standard OAL Autocoding system, allowing for easy monitoring of production performance. The system also links to the site’s Domino inkjet printers and Markem case printers to ensure the correct dates are printed on each pack, ready for shipment.
Results
Autocoding has eliminated any risk of packaging errors; 100% read rates prevent incorrect tins being packed and print control has ensured the correct dates are applied. False line stoppages due to ‘no reads’ have been removed improving production performance.