Contract blender installs single printing system for multiple lines

Maltra Foods, established in 1966, was originally primarily involved in the manufacture of cocoa-based beverage drinks, which led to the company becoming an importer of a range of cocoa ingredients. Since then, Maltra has successfully diversified and today is a leader in contract blending, offering powdered consumable products from Chai tea and chocolate to protein powders and soft serves. Over the past decade it has become one of the largest manufacturers in its field distributing throughout Australia, New Zealand and parts of Asia including Malaysia, Indonesia, Japan and Korea.

Recently it was decided that Maltra needed an automatic, centralised printing system for its seven production lines to ensure detailed information and delivery accuracy for customers on its continually expanding SKUs. The company wanted a cost-effective, easily expandable solution that removed paperwork, increased productivity and accuracy, and enabled it to deliver on the best possible customer service.

Maltra Foods needed a centralised printing system so it could use standardised printing formats, reduce operator error and improve consistency.

“With those ever-increasing SKUs has also come growing demand from our customers for more detailed information and accuracy on delivery,” explained Roman Eydlish, Maltra’s operations manager.

“So we needed a centralised printing system; and on top of that, we also wanted to move from a paper-based system to an automated one so we could use standardised printing formats, reduce operator error and improve consistency, thereby increasing our overall efficiency and productivity.”

With three existing Linx continuous inkjet printers (CIJ) from Matthews Australasia - the latest being a CJ400 - coding best-before dates and batch numbers onto foil pouches of powder, Maltra approached Matthews for a coding solution.

Matthews recommended a Viacode high-resolution printer; and at the same time, the blending specialist also installed a SAP ERP system.

Along with ever-increasing SKUs and growth, Maltra Foods’ customers were also demanding more detailed information on cartons.

Maltra has seven processing rooms and each needed coding facilities, so Matthews installed a print-head in each room, with all seven networked to a single, centrally located controller. The Viacode solution can also be simply expanded in the future, as Maltra grows, to add more production lines.

“The Viacode Hi-Resolution Printer can print in a two-line format, doing it all from the convenience and security of a centralised library. This helps reduce the threat of data loss, while providing the freedom to print additional information on all products,” said Eydlish.

The printer is located at the end of the production line, following the automated box-erecting machine, and codes onto carton surfaces. Maltra Foods uses it daily across one or two production runs, with a current throughput of 70-100 items/min. The information coded includes: best-before codes, batch numbers, Julian codes, reference numbers, establishment numbers and product names.

Each of Maltra Foods’ seven processing rooms needed coding facilities, so Matthews installed a print-head in each one, with all seven networked to a single, centrally located controller.

Quality assurance manager Charik Urencio says staff find it easy to use, adding, “This system makes my life easier - that’s one less item I have to be concerned about in the production process.”

Eydlish says for Maltra Foods, investments in solutions such as the Viacode high-resolution printer are not just about increasing accuracy, reducing risks for operational errors or even productivity. “It’s about keeping a promise made to clients that it will provide and deliver the best service possible.”