Blog | packaging

March 29, 2023 - RAVENWOOD

Gressingham Slashes Carbon Footprint With Linerless

Renowned duck brand, Gressingham Foods, has teamed up with Ravenwood Packaging and linerless printer, Coveris, for driving its sustainability initiatives by adopting linerless labels across its range of duck portion products. The packaging revamp has allowed the UK’s main supplier of duck to save on manpower and slash its carbon footprint, saving over 24 tonnes of waste material per year. Carbon emissions have also been dramatically reduced with a saving of 3,400 kg of CO2 per annum.

The new linerless labels are produced by Coveris and replace Gressingham’s labour-intensive and time-consuming three-tier packaging process. Previously thermoformers would apply film to portions of duck and then cardboard sleeves were then hand applied to each pack. A third stage was sometimes used to apply a promotional label which meant up to six people could be involved.

For the label application, Gressingham opted for a Ravenwood Nobac 5000V linerless sleever for automating the entire process. Dave Gooding, Ravenwood’s Commercial Director said: “The 5000V is perfectly suited to Gressingham’s products and by switching to linerless means the sleeves are now automatically applied, with less waste, coupled with a reduced sleeve material weight. Linerless is highly sustainable and has resulted in Gressingham’s emissions being massively reduced.”

In addition to C-wrap labels, Ravenwood’s Nobac 5000V is the ultimate solution for labeling whole birds including a variety of MAP and VSP trays as well as shrink wrap. The applicator is also equipped to apply shaped labels and products that feature extended back panels on C-wrap and trayed whole birds. A maximum pack height of 125mm applies, making this machine ideal for protruding products. “Working with Coveris and Ravenwood has been hugely successful, with both companies understanding our two-part vision to reduce our carbon footprint, whilst retaining our premium look and feel,” explains Rebecca Alderton, Brand Manager at Gressingham Foods.

“As one of the only independent brands in the meat, fish and poultry aisle, we needed the linerless labels to mimic the appearance of the sleeve packaging as much as possible in order to retain our brand recognition and shelf appeal, whilst proving that more eco-friendly packaging changes can be achieved in the sector,” adds Rebecca.

The new packaging is set to roll out across all Gressingham retail outlets in March 2023.

Based in Suffolk, Gressingham foods was founded in 1989 and produces a range of products including fresh duck and poultry, Aromatic Crispy Duck Kits and a Bistro range featuring a wide selection of delicious duck classics. Gressingham Duck® products are available in Tesco, Asda, Sainsbury’s, Waitrose, Morrisons and Ocado.

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March 9, 2023 - Ravenwood

Ravenwood to Showcase Automated Optical Inspection and Linerless at Interpack

It’s all systems go! The leaders in linerless and pack inspection will be exhibiting at Interpack in Düsseldorf. Ravenwood will be demonstrating the Nobac 5000V vertical linerless applicator, Nobac 5000A automatic linerless applicator and VR Vision System, for automated optical inspection on food products.

All three machines are standalone but the 5000A and VR can be linked for label application and automated optical inspection. Ravenwood will also be demonstrating a revolutionary quality management system. A representative from QUOR will be joining Ravenwood on their stand for showing how this software communicates with the VR Vision system.

Let’s take a look at the systems Ravenwood will be demonstrating at this year’s show.

Nobac 5000V Vertical Linerless Applicator

Ravenwood is excited to showcase the all new Nobac 5000V. Unlike other machines that fall under the Nobac 5000 range, this particular applicator features the mandrel to the side of the product conveyor, changing it to a vertical labeler. Essentially, products are driven ‘through’ the label, so allowing for difficult applications and increased protrusions. Subsequently, this particular model is ideal for the labeling of whole birds.

Although, the 5000V is restricted to applying C Wrap linerless labels, it can label a variety of MAP and VSP trays, as well as shrink wrap. A maximum pack height of 125mm applies with excellent application speeds at over 80ppm.

There is also the option to link to weigh scales, as well as printing catch weight and fixed weight products.

Nobac 5000A Automatic Linerless Applicator

Ravenwood will also introduce and showcase its automatic linerless applicator, the Nobac 5000A. Building its core foundation on the Nobac 5000 range, the new automatic sleever is a customer optional addition that automates switching between products, pack sizes and label size. This is thanks to its motorized adjustment of top lay belts, infeed guides and height adjustment.

Operators, factory management software and weigh-price labelers can select pre-programmed tray sizes to allow the machine to move automatically, to new positions, freeing up time for the operator to load labels. The Nobac 5000A will be linked to the VR Vision system.

VR Vision System – Automated Optical Inspection

Joining the 5000A is Ravenwood’s VR System. Both machines will be linked for demo purposes to show label application on the 5000A and then pack inspection on the VR. Once the food pack has been labelled and travelled through the 5000A, it will be analysed by the Vision system. With unrivalled inspection and quality assurance software, the VR utilizes the latest image processing technologies to analyse each finished pack when leaving the production line.

As mentioned, the VR has been built as a standalone technology but can also be integrated into a line system. Each pack is individually inspected against a pre-set standard, programmed into the user-friendly interface. Any packs that fail to meet the set criteria are automatically rejected into a secure bin with the reject confirmed and recorded for tracking.

Bar codes, use-by dates and traceability codes are analysed and confirmed without the need to interrupt the packs whilst in flight. In addition to these checks, 2D codes for encoded stock rotation or label ID can be read on-line.

Pack speeds up to 130 per minute are achievable to perfectly match any existing line processing equipment. The VR also has the ability to integrate an upstream checkweigher. This allows for all rejected packs to be collected in one area, but in separate bins.

QUOR Quality Management System

QUOR’s revolutionary quality management software will be working in synergy with the VR system. The software makes compliance straightforward, paperless and easy to operate.

The QUOR management system integrates seamlessly for all manual inspections and processes including on-line quality checks that would otherwise be entered manually. QUOR can talk to the VR Vision system for criteria such as in-line recording, verification and product checks, for complying with the VR’s existing software.

QUOR allows for product selection and storage of quality data. Products are selected for checking on the QUOR interface resulting in the VR being automatically set up without further intervention. All line quality data is uploaded, captured, stored and reported for analysis, and traceability. Images of all packs produced including rejected packs are recorded and retrieved to further enhance quality assurance and for satisfying audit processes. Retailer compliant KPI reports generated and submitted are available at the click of a button. Data is retrieved securely both on and offsite, via PC based software or the QUOR quality management app.

Imagine having your KPI report available in real time – anytime and anywhere? Well, the QUOR system does just that.

Interpack 2023

Interpack is reported to be the world’s largest trade fair and a global trendsetter for the packaging sector. From sustainability to digitalization, the focus is on packaging materials, packaging machines and related process technology. Market sectors include food, beverage, confectionery, bakery, pharmaceutical, cosmetics, non-food and industrial. Interpack 2017 experienced record breaking numbers with 2,865 companies exhibiting.

Find team Ravenwood in Hall 08B | Stand 8BD35.

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February 24, 2023 - RAVENWOOD

Ravenwood’s Nobac 5000V – the Ultimate Linerless Solution for Whole Birds

You’d be forgiven for doing a double take on the aesthetics of the new Nobac 5000V. Whilst Ravenwood’s latest linerless applicator has taken on a totally different look visually, mechanically, it still operates and performs in the same way, when compared to its Nobac 5000 counterparts.

Why has the Nobac 5000V been engineered in this styling and what does the ‘V’ stand for?

Unlike other machines that fall under the Nobac 5000 range, this particular applicator features the mandrel to the side of the product conveyor as opposed to it being positioned above. By placing the mandrel to the side, allows the labels to be applied vertically and this is where the ‘V’ comes from. The 5000V is a vertical labeler. Essentially, products are driven ‘through’ the label, so allowing for difficult applications and increased protrusions, making it ideal for the labeling of whole birds.

How does the Nobac 5000V compare to other machines in the Nobac 5000 range?

As explained, visually the 5000V looks completely different, with the label mandrel being positioned to the side. It is also more compact, with a smaller footprint at just over 1 meter square.

In terms of the overall mechanical workings, the labeler features the same flexibility as other models in the range. Although, the 5000V is restricted to applying C Wrap linerless labels, it can label a variety of MAP and VSP trays, including shrink wrap and trayed whole birds. It is also equipped to apply shaped labels. Due to this unique label presentation, the 5000V can carry out applications that are not possible with other machines which includes extended back panels on C Wrap and whole birds. A maximum pack height of 125mm applies, making this machine ideal for protruding products.

The applicator also boasts excellent application speeds at over 80ppm. And as with all other machines in the 5000 range, there is the option to link to weigh scales, as well as printing catch weight and fixed weight products.

Watch the video here: https://youtu.be/S1zzbynlgBI

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February 21, 2023 - RAVENWOOD

Retailers and Packers Replace Plastic with Linerless for Fruit Packaging

Ravenwood’s linerless Fruit Lid is fast becoming the label of choice for brand owners, retailers and packers for their fresh produce packaging.

The Fruit Lid when applied to a carton board tray, forms a complete pack for the supply of fresh fruit and vegetable products. The food grade packaging concept replaces the need for plastic flow wrap and single use plastic bags. Subsequently, the entire pack is highly sustainable and 100% kerbside recyclable. The new fruit pack concept is generating much interest with packaging technologists around the world.

During the last year, Ravenwood has supplied its Fruit Lid to many high profile retailers including Iceland, Waitrose and Ocado as well as tomato packer, Tomeco. The Fruit Lid has been applied to kiwis, apples, pears and tomatoes. Further Fruit Lid projects are in the pipeline.

Paul Beamish, Ravenwood’s Managing Director said: “Our linerless Fruit Lid can help brand owners tackle the problems associated with single use plastic. Across a global scale, we use a horrendous amount of this material in our daily lives. Plastic has got itself a really bad name but the problem stems from how we discard it. Fortunately, efforts are now in place to tackle this problem in creating a circular economy for this material.”

The Fruit Lid is applied by Ravenwood’s Nobac 5000L linerless applicator which is designed to run and apply labels to a wide range of carton board tray sizes. Date and batch coding requirements can also be added by purchasing and integrating a Viper TIJ. Average pack speeds are around 60-65 per minute, with a maximum speed of 70 ppm, depending on the size of the Fruit Lid, tray and products. All linerless projects, from label design concepts and tray style, right the way through to label application and launch, is handled collectively by Ravenwood and its network of printers and machinery distributors. Depending on where in the world you are located.

Ravenwood operates and supplies its linerless technology across 25 countries around the world with 21 printers and 38 machinery distributors. The packaging and labelling specialist supplies the complete linerless solution, known as the "Circle of Linerless." Brand owners, retailers and packers can benefit from faultless linerless labels, a performance guarantee, fully approved sustainable materials, 24/7 support and disaster recovery.

The launch of the linerless Fruit Lid is well timed as France bans plastic packaging for all fruit and vegetables from January 2022. Following on from France, Spain is also preparing its new legislation to come into effect from 2023. As we are all too aware, plastic pollution is a global issue and despite efforts to suitably dispose of waste, every year thousands of tons of bottles, wraps and other plastics make their way into the environment and the oceans.

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December 16, 2022 - RAVENWOOD

Dynamic End of Line Product Inspection for Unrivaled Inline Quality Control

Thanks to the integration of Ravenwood’s high speed VXR Vision Pack Inspection System and a Starflex Flexi C – RW Checkweigher, you can harness the power for dynamic end-of-line product inspection and quality control.When combined, the high-precision mechanical technology of these two machines, boast a pioneering and innovative approach to end-of-line product inspection. The seamless integration of these technologies also significantly increase production speeds for exceptional accuracy and flexibility.

Food packs initially pass over the Starflex Flexi C – RW Checkweigher, which monitors pack weights, rejecting any products that are over or under the set weight, within the required legislation. The Vision element of the machine detects faulty labels including printing errors and poor-quality print, as well as label position, quantity, and orientation. Bar codes, use-by dates and traceability codes are also checked. The core functionality of the VXR’s x-ray inspection remains the same, boasting maximum safety and guarantees for detecting dangerous foreign bodies such as metals, glass, stones, bones, and high-density plastics. Packs that are deemed to feature dangerous foreign bodies, faulty print and incorrect in weight, are rejected into two lockable reject bins. One bin is dedicated to X-ray rejects and the other is used for weight and Vision rejects.

Ravenwood’s high speed VXR has been developed further with the addition of two side by side reject bins. Subsequently, the new set up allows for greater reject capacity and faster inspection pack speeds.

When combined the VXR and Checkweigher provide:

• Dynamic Checkweighing and monitoring.

• Inline Vision inspection of labelled packs using images captured from a top, bottom, or top and bottom camera.

• X-ray inspection for detecting dangerous foreign bodies such as metals, glass, stones, bones and high-density plastics.

• Increased speeds from 120 packs to (up to) 140 packs per minute.

• Greater reject capacity thanks to the side-by-side reject bins.

• Higher running speeds for reduced operator intervention.

• The option to integrate QUOR quality management software.

Watch the video here: https://www.youtube.com/watch?v=X-olzolp3f0

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November 17, 2022 - RAVENWOOD

JCS Fish Fully Automate Production with Linerless

JCS Fish has fully automated its packaging and labeling lines, and has also replaced its manually applied cardboard sleeves with linerless. Ravenwood’s linerless technology has been rolled out across its award winning Big Fish range.

THE CHALLENGE

The seafood specialist was manually thermoforming packs of salmon and trout and then hand applying cardboard sleeves to each pack. A third stage would then involve manual application of a self-adhesive secondary date label. The process was both labor intensive and time consuming. Four people were working on the thermoformer packaging line and then a further three additional people were responsible for the sleeving and labeling. JCS recognized that this was impractical and decided to upgrade its lines to fully automate the process. Ultimately, the decision would speed up production, streamline operations and allow for workers to be redeployed throughout the business.

Furthermore, adopting a more sustainable method of labeling was also preferable as JCS was sending its label liner to landfill, contributing to its carbon footprint.

THE SOLUTION

JCS decided to fully automate both its skin pack and labeling lines by opting for a Multivac R105 Thermoform skin pack machine and a Nobac 5000 linerless applicator for the labeling. Both machines came highly recommended as stand-alone technologies as well as working in synergy together for fault-free operation on packaging and labeling lines.

Linerless is highly sustainable. Due to the absence of the backing paper, there is no need to dispose of, incinerate or pay for expensive liner recycling programs. Subsequently, JCS no longer needs to send label liner to landfill which has resulted in a marked reduction to its CO2 emissions.

The Linerless Label and Tray

JCS decided to opt for two different sized trays. A smaller tray for a single salmon fillet and a slightly larger tray for two fillets. Ravenwood’s keyline designer got to work on the label design templates. Two D-wrap linerless labels were then created.

Label Design

Once keylines were drawn up, the template and label design were outsourced to a JCS preferred design agency.

UK Linerless Printer

Coveris UK: www.coveris.com

Nobac 5000 Linerless Applicator

JCS opted for a standard Nobac 5000 applicator for applying linerless to its salmon and trout packs. A Falcon TTO Coder was also integrated for printing use-by dates to the linerless label. This alleviated the need for manually adding this information by way of a secondary self-adhesive label.

The Nobac 5000 is configured to work in standalone mode, but should JCS decide to move to catchweight labeling, there is the option to connect to a weigh-price labeler. This will future-proof the business.

Key Features:

• Inline machine designed for maximum flexibility.
• Eliminates the need to turn the packs.
• Capable of applying 50mm – 120mm wide labels.
• Pack speeds of up to 150ppm* are achievable (*dependent on label specification).
• Linerless labels allow for more labels per roll, resulting in longer runs and increased production time.
• With automated sleeving, customers can benefit from reduced costs and labor requirements.
• Wasted printed labels on changeovers minimized by printing at point of application.
• Eliminate wasteful and non-recyclable backing paper.
• Reduce landfill disposal costs.
• Linerless reels weigh up to 40% less and take up 40% less space than those with carrier backing paper plus the space required to house the pre-formed cardboard sleeves.

THE SUCCESS STORY

Previously, the Big Fish production line was labor intensive and time consuming but since implementing the new Multivac R105 Thermoform skin pack machine and the Nobac linerless applicator, processes are now fully automated. Subsequently, this has resulted in less downtime, and increased production efficiency with packaging and labeling application speeds increasing significantly. Previously, with the manual cardboard sleeve application, speeds of just 12 packs per minute were being achieved. However, since switching to Ravenwood’s linerless technology, JCS is seeing speeds of 50 to 60 ppm. The new R105 Thermoform skin pack machine has also increased skin pack production to 25 ppm and the Falcon Coder adds use-by dates automatically.

JCS Commercial Manager, Jack Coulbeck reports that the Nobac 5000 is user friendly, low maintenance and extremely efficient. With increased packaging and labeling speeds, JCS is now better equipped to meet production deadlines and delivery timescales for satisfying the needs of its retailers. The award winning Big Fish range is available to purchase from Ocado and small independent farm shops.

Being a climate conscious organization, Ravenwood’s linerless technology is a good fit for their product offerings. The JCS factory is BRC AA-Grade rated and they hold a top Green rating under the Investors in the Environment (IiE) scheme.

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November 4, 2022 - RAVENWOOD

Ravenwood’s Nobac 5000 Just Got Smarter

The Nobac 5000A is the 9th addition to join the diverse and world-leading range of Ravenwood linerless applicators.

Building its core foundation on the Nobac 5000 linerless label applicator range the new automatic sleever is a customer optional addition that automates switching between products, pack sizes and label size, thanks to its motorised adjustment of top lay belts, infeed guides and height adjustment. Operators, factory management software and weigh-price labellers can select pre-programmed tray sizes to allow the machine to move automatically, to new positions, freeing up time for the operator to load labels.

Ravenwood has a diverse range of Nobac applicators, designed for maximum flexibility, for applying Ravenwood linerless labels. In addition to sleeving fixed-weight packs, these machines can link to weigh-scales from a range of manufacturers for variable-weight products, in addition to check-weighing. Labels are supplied in a range of weights and materials, including paper and polypropylene. All adhesives are optimised for individual products. Machine variants are dependent on product type and specification.

Watch the Nobac 5000A Auto in action on YouTube:

https://www.youtube.com/watch?time_continue=5&v=IcXVXQETwfk&feature=emb_logo

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October 21, 2022 - RAVENWOOD

Retailers and Packers Replace Plastic with Linerless for Fruit Packaging

Ravenwood’s linerless Fruit Lid is fast becoming the label of choice for brand owners, retailers and packers for their fresh produce packaging. The Fruit Lid when applied to a carton board tray, forms a complete pack for the supply of fresh fruit and vegetable products. The food grade packaging concept replaces the need for plastic flow wrap and single use plastic bags. Subsequently, the entire pack is highly sustainable and 100% kerbside recyclable. The new fruit pack concept is generating much interest with packaging technologists around the world.

During the last year, Ravenwood has supplied its Fruit Lid to many high profile retailers including Iceland, Waitrose and Ocado as well as tomato packer, Tomeco. The Fruit Lid has been applied to kiwis, apples, pears and tomatoes. Further Fruit Lid projects are in the pipeline. Paul Beamish, Ravenwood’s Managing Director said: “Our linerless Fruit Lid can help brand owners tackle the problems associated with single use plastic. Across a global scale, we use a horrendous amount of this material in our daily lives. Plastic has got itself a really bad name but the problem stems from how we discard it. Fortunately, efforts are now in place to tackle this problem in creating a circular economy for this material.”

The Fruit Lid is applied by Ravenwood’s Nobac 5000L linerless applicator which is designed to run and apply labels to a wide range of carton board tray sizes. Date and batch coding requirements can also be added by purchasing and integrating a Viper TIJ. Average pack speeds are around 60-65 per minute, with a maximum speed of 70 ppm, depending on the size of the Fruit Lid, tray and products. All linerless projects, from label design concepts and tray style, right the way through to label application and launch, is handled collectively by Ravenwood and its network of printers and machinery distributors. Depending on where in the world you are located.

Ravenwood operates and supplies its linerless technology across 25 countries around the world with 21 printers and 38 machinery distributors. The packaging and labelling specialist supplies the complete linerless solution, known as the ‘Circle of Linerless’. Brand owners, retailers and packers can benefit from faultless linerless labels, a performance guarantee, fully approved sustainable materials, 24/7 support and disaster recovery.

The launch of the linerless Fruit Lid is well timed as France bans plastic packaging for all fruit and vegetables from January 2022. Following on from France, Spain is also preparing its new legislation to come into effect from 2023. As we are all too aware, plastic pollution is a global issue and despite efforts to suitably dispose of waste, every year thousands of tons of bottles, wraps and other plastics make their way into the environment and the oceans.

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October 21, 2022 - RAVENWOOD

Reflex Group Adds Linerless to Ireland Facility

Ravenwood is pleased to announce its latest Com500 coater install with Reflex Group, one of its long established UK linerless printers. The linerless converting equipment has been installed at the Reflex site in County Wicklow and will allow Ravenwood to provide its approved linerless labels to the growing number of customers in this region. Ravenwood’s Com500 is the only coating system dedicated to running and delivering high quality Ravenwood linerless labels. These labels are pressure sensitive with no need for backing paper or release liner. Subsequently, the technology is highly sustainable as there is no requirement for landfill, incineration or recycling programs. Labels produced by the Com500 are designed to work to the correct specification required for label application by Ravenwood’s Nobac 5000 linerless applicator range.

Ian Kendall, Reflex Group CEO Said: “Our customers are looking to reduce waste and packaging costs in addition to increasing line productivity. The Nobac 5000 range of linerless applicators, and associated equipment such as the Vision system, offer the most efficient way to put information on, and decorate a pack. The system has been proven time and time again to be by far, the best option. We are delighted to be able to be that bit closer to our Irish customers with the installation of the Com500.”

The demand for linerless is increasing exponentially, across a global scale with many brand owners, retailers and supermarkets now switching to this method of labelling. Linerless labels suit a wide range of market sectors including meat and fish, fresh produce, salad pots, oven and ready meals, food to go, as well as bakery and desserts. Paul Beamish, Ravenwood’s Founder and Managing Director said: “This is an exciting time for Ravenwood and Reflex. We have both enjoyed a long and successful business partnership and with the new coater install, this can only strengthen our relationship further for increasing sales in Ireland.”

Formed in 2002, Reflex Group joined Ravenwood as an approved linerless printer in November 2008. The packaging and labelling solution specialist is made up of 26 sites with the new County Wicklow facility being the latest location to join the Reflex family. In addition to linerless, Reflex serves a broad range of customer sectors for producing self-adhesive, shrink sleeve, flexible packaging, in-mould labels, artwork and design.

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September 2, 2022 - RAVENWOOD

Ravenwood’s Linerless Technology for Food To Go Packaging

A great linerless success story for all parties involved. Ravenwood was approached by the UK’s fastest growing food retailer and its convenience food producer, for tackling a unique food to go packaging concept. This project champions sustainable packaging and 100% kerbside recyclability across its nutritionist approved range of ready meals. A climate conscious combination.

The new fresh ready meal range which boasts five different options, is prepared in two steps and ready to eat in just three minutes. Options include vegan and non-vegan meals for lively lunches and speedy suppers.

THE CHALLENGE

The retailer and its producer approached Ravenwood to tackle a double tray ready meal linerless labelling project. This unique packaging concept is the first of its kind in the ready meal sector. Heatable food features to the top tray and salad to the base.

Labelling two trays is a challenge in itself but these trays are also different sizes. Ravenwood needed to ensure that the trays, when positioned together, would be rigid and without movement, for accurate label application on the Nobac 5000 applicator. Sloppy label application can result in labels having to be adjusted by hand and this can result in significant downtime. Ravenwood also needed to ensure that the products, once labelled, would remain intact, withstanding travelling to supermarket for clean presentation on shelf.

The final hurdle was the recess located to the larger base tray. Normally food trays are flush with the edge, but this wasn’t the case. Subsequently, Ravenwood’s keyline designer had to make further allowances when drawing up the label template.

THE SOLUTION

The Trays

The packaging consists of two trays and features heatable food to the top and a fresh salad to the base.

• Both trays of different sizes made from FSC sustainably sourced materials.

• Trays are made from natural kraft and rPET anti-mist lids.

• The trays ‘slot’ together on top of each other with the larger tray to the base.

• Base tray is manufactured with a recess.

• Both base and lid are 100% kerbside recyclable.

Modification to the Tray

The lid of the base tray (see image below) had to be modified so that the smaller tray could sit on top without moving. As you can see, the lid was altered and now features a raised section that fits neatly into the base of the smaller top tray. This slight adjustment now allows the trays to slot together for improved sturdiness for secure labelling and display on supermarket shelves.

The linerless label alone, cannot hold these two trays together.

The Label

The food retailer decided to appoint one of Ravenwood’s UK linerless printers, Reflex Labels, for the design and production of the label.

After a series of trials, an oversized d-wrap linerless label was given the go ahead. Ravenwood’s keyline designer then designed the label for application across both trays. Five vibrant designs were then produced by Reflex Labels.

Linerless is unique and features no backing paper, unlike its self-adhesive counterparts. Subsequently, there is no need to dispose of the label liner. Current disposal methods include burying the liner in landfill, liner recycling programmes and liner incineration. All of these options are costly – both to the pocket and the planet.

The Label Adhesive

Pressen 4301 was recommended as this is a tackier adhesive, generally suited to applications where there is less surface print area. With the double tray concept, it was felt that this adhesive would be perfectly suited for increased adhesion and improved application across both trays.

The Linerless Applicator Machine

Ravenwood supplied two Nobac 5000 linerless applicators with speeds of 50ppm achievable.

The build process has a low environmental impact with over 90% of the sleever’s weight produced in the UK. All components are machined on site at Ravenwood’s Norwich factory or sourced within a 4 mile radius. Once built, the 5000 boasts a very modest footprint at just 1.5 metres in width. The applicator is extremely versatile and user friendly:

• Modular construction allows bolt-on or off, twin-head option for non-stop operation.

• Independent driven belt transfer system for easier set up, for different glue line positions.

• Label reel braking system provides advanced reel control especially on different substrates, such as PP or thicker boards.

• Optional motor adjustment.

• Capable of labelling fixed weight products or linking to weigh-scales for variable-weight or check-weight products.

• Optional thermal inkjet coding for the edge of cardboard trays.

• Utilises thin board sleeves with various adhesives optimised for specific products.

• Application speeds can reach 150ppm (dependent on tray and product).

• Labels can be supplied in a range of weights and materials.

• Many label formats including top labelling, die cut and shaped.

Ravenwood has also now launched the Nobac 5000 Auto. The 5000 Auto is a customer optional addition that automates switching between products, pack sizes and label size, thanks to its motorised adjustment of top lay belts, infeed guides and height adjustment.

SUCCESS STORY

The entire project, from initial enquiry to products landing on shelf, took just 6 months to complete. Ravenwood and its printer, Reflex Group, worked in synergy for meeting this timescale.

The new ready meal range and innovative double tray concept has ticked just about every box possible for a food retailer. With the combination of nutritionist approved foods, sustainably sourced packaging materials, 100% kerbside recyclability, the project has all the ingredients for a great climate conscious success story. Most importantly, the range has also been very well received by the retailer’s customers.

The value of the UK food to go sector is expected to reach £23 billion by 2025, driven by expansion, new product development and growth in channels such as delivery, according to Lumina Intelligence. Ravenwood is seeing a surge in linerless enquiries from this sector.

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April 27, 2022 - RAVENWOOD

Ravenwood to Launch Automatic Linerless Label Applicator at IFFA

Ravenwood Packaging is set to unveil its latest linerless innovation at this year’s IFFA. The Nobac 5000 Auto (linerless label applicator) will feature alongside the VR Inspection System. Both machines will be on demo throughout the show.

The Nobac 5000 Auto and VR system can be stand-alone technologies or seamlessly integrated for the faultless application and inspection of linerless labels across a diverse range of foods including meat, fish, plant based proteins, ready meals, salad pots, desserts and fresh produce.

Let’s take a look at Ravenwood’s latest linerless adaption – the Nobac 5000 Auto. The 5000 Auto is now the 9th addition to join the diverse and world-leading range of Ravenwood linerless applicators. Building its core foundation on the Nobac 5000 linerless label applicator range released in 2020, the new Nobac 5000 Auto is a customer optional addition that automates switching between products, pack sizes and label size, thanks to its motorised adjustment of top lay belts, infeed guides and height adjustment. Operators, factory management software and or weigh-price labellers can select pre-programmed tray sizes to allow the machine to move automatically, to new positions freeing up time for the operator to load labels.

Joining the 5000 Auto will be Ravenwood’s VR Inspection System which offers unrivalled brand and consumer protection. Directly after the packs have been labelled, the VR will then inspect to identify errors and reject any packs where faulty labels are detected. The VR does this by optical vision inspection. Faults are largely due to poor quality print and inaccuracies, but the VR analyses even further and will check for label position, quantity and orientation for guaranteed consistency across all packs. Furthermore, even small print such as barcodes, use-by dates and traceability codes are also inspected. In fact, all printed information. The process offers complete peace of mind, alleviating the need for manual analysis which can lead to faults going unchecked.

David Gooding, Ravenwood’s Commercial Director said: “It’s great to finally be getting back to normal in attending events in person. I know that the team is really looking forward to both the show itself and the launch of the 5000 Auto. ”

Gooding added: “It will also be the first time we have exhibited at IFFA so we are hoping it will prove to be a great success and the first of many for Ravenwood.”

IFFA takes place every 4 years and is the world’s leading trade fair for the meat industry with the 2022 show opening up to the alternative proteins markets. The show is very well established with this year marking IFFA’s 71st anniversary. The show covers the entire supply chain for processing, packaging, selling and distribution and offers a great platform for networking opportunities across a global scale. Around 900 exhibitors will be in attendance from over 40 countries. IFFA will run from the 14 – 19 May 2022.

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April 6, 2022 - RAVENWOOD

Ravenwood Proudly Presents It's Latest Linerless Mission: THE LINERLESS CO2 SAVINGS CALCULATOR!

We have created a CO2 Savings Calculator to prove how much CO2 can be saved when comparing linerless to self-adhesive labels.

Three values are entered into the calculator:

• Measurement A (the longest length of the label)
• Measurement B (the shortest)
• Label Quantity

Ravenwood researched how much CO2 is emitted when manufacturing a tonne of backing liner for self-adhesive labels. A total of 2,200kgs of CO2 per tonne is emitted to produce 1,000kgs of liner paper (source: AWA and Avery Dennison).

• The calculations are based on 3, 4 and 5 adhesive / silicone lines.
• Our calculator displays the CO2 savings in kgs and a percentage value.

Check out our calculator at the link below and see the savings for yourself!

https://www.ravenwood.co.uk/co2-calculator/

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March 4, 2022 - RAVENWOOD

Ravenwood to Showcase Linerless Fruit Packaging at Fruit Logistica

Ravenwood Packaging will exhibit its linerless and vision inspection technologies at Fruit Logistica in April. The ‘leaders in linerless’ will have two machines on demo – the Nobac 5000L ‘fresh produce’ linerless applicator and the VR Inspection System. The perfect combination for the packaging of fruits and vegetables.

The Nobac 5000L and VR system both work in synergy for the labelling and inspection of all foods including fresh fruits and vegetables. Both machines can be stand alone or seamlessly integrated for the labelling and inspection of packs.

The fresh produce linerless applicator is the latest 5000 machine variant to join Ravenwood’s linerless ranks. The 5000L applies ‘Fruit Lid’ linerless labels to carton board trays. When combined, the food grade Fruit Lid and tray, forms a complete pack for labelling and packaging of fresh fruit and vegetable products. The pack concept replaces the need for plastic flow wrap and single use plastic bags. As a result, the entire pack is highly sustainable and 100% kerbside recyclable. With various tray sizes available to suit a wide range of requirements coupled with the option of bespoke Fruit Lid label designs to fit, the pack concept offers a high degree of flexibility. Furthermore, if retailers are looking for high application speeds, then the 5000L will not disappoint with speeds up to 70ppm. When considering the benefits overall and most importantly, the elimination of plastic packaging, it’s no surprise that the new pack concept is generating much interest with packaging technologists around the world for the packaging of fruits of vegetables.

Joining the Nobac 5000L on stand will be Ravenwood’s VR Inspection System which offers the ultimate in safeguarding for brand and consumer protection. Directly after the packs have been labelled, the VR will then identify errors and reject any packs where faulty labels are detected. The VR does this by optical vision inspection. These faults are largely due to poor quality print and inaccuracies, but the VR analyses even further and will check for label position, quantity and orientation for guaranteed consistency across all packs. Moreover, even small print such as barcodes, use-by dates and traceability codes are also inspected. In fact, all printed information. Collectively, the process offers complete peace of mind, alleviating the need for manual analysis which can lead to faults going unchecked.

David Gooding, Ravenwood’s Commercial Director said: “Fruit Logistica is a new show for us. The new fruit lid and carton board pack concept has now opened up a completely new market for Ravenwood and its distributor, and printer network.”

Gooding added: “This will also be the first time we have exhibited the VR Inspection System.”

Find Ravenwood on stand: 6.1/B06.

Fruit Logistica is the world’s leading trade fair for the fresh fruit and vegetable industry and will take place in Berlin from the 5 – 7th April 2022. At the 2020 show, more than 3,300 exhibitors from 91 countries presented their products, services and technical solutions with around 73,000 trade visitors from 135 countries in attendance. Fruit Logistica represents the entire value-added chain for the fresh produce industry, from producer to point of sale.

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February 18, 2022 - RAVENWOOD

Bella and Duke Reduce Packaging Shipping Costs by 98% with Linerless

ABOUT BELLA AND DUKE

Bella and Duke was founded in 2017 by Tony Ottley and Mark Scott. Both Tony and Scott had lost their dogs to cancer and were convinced that the processed foods their dogs had eaten their entire lives could have potentially caused the disease. After carrying out extensive research on raw and natural dog food and finding there was a gap in the market, they decided to take action and create their own.

Their foods have been developed with animal nutritionists and vets to ensure the utmost quality and all ingredients are sourced from local suppliers. During the last four years, business operations have gone from strength to strength, and Bella and Duke now deliver frozen raw dog and cat food all over the UK and are the UK’s largest D2C pet wellness brand.

THE CHALLENGE

Tony and Mark were not happy with their current packaging which comprised a self-adhesive top label and ‘ice cream’ style tub. Both of these packaging elements needed addressing.

Self-Adhesive Top Label

The self-adhesive top label would only allow for print on the face of the label. Tony and Mark wanted the option for an increased surface print area but with the underside of the label stuck to the pack, space was limited.

‘Ice Cream’ Food Tub

Bella and Duke’s recipes were prepared and packaged by a third party. The packer packed the raw food into ‘ice cream’ style tubs with a lid. This form of packaging was very dense in plastic and the lack of overall control meant that the process was clocking up food miles, time, and cost. And subsequently, the company’s carbon footprint.

THE SOLUTION

Switching from Self-Adhesive to Linerless

Bella and Duke switched from a self-adhesive top label to a c-wrap linerless label.

Linerless labels feature double the surface print area with both the face and underside free for print. Bella & Duke’s linerless labels are currently utilising the face of the label for print but there are plans to make use of the reverse. This will be used for adding additional product information, including nutritional facts, healthcare advice, marketing mechanics and promotions.

Linerless labels do not feature label liner which means the need to landfill, incinerate or recycle the backing paper is completely eradicated.

Bella and Duke’s labels are printed by a Ravenwood approved linerless printer:

The Printing Company: Reflex

reflexlabels.co.uk

Tony states that Reflex has been extremely accommodating, providing support and advice both on label design and ensuring the seamless transition from the previous method of label application to the Nobac 5000.

Nobac 5000 Linerless Applicator with ‘Plug & Play’ Second Head

Bella and Duke purchased a single head Ravenwood Nobac 5000 label applicator for applying its c-wrap linerless labels. The ‘Plug and Play’ element is a 2nd head unit added to the original head which when combined, transforms the applicator into a twin head machine.

The Nobac 5000 ‘Plug and Play’ twin head unit has been developed to meet the needs of those customers whose labelling requirements have increased and a single head Nobac 5000 doesn’t meet production requirements. The twin head extension unit can resolve this problem by alleviating the need to purchase an additional full Nobac 5000T Twin Head machine.

Planning investments based on production requirements reduces the risk of buying machinery that could potentially be underused. The Nobac 5000 ‘Plug and Play’ extension has enabled Bella and Duke to increase production and benefit from zero downtime.

Both the Nobac 5000 ‘Plug and Play’ with a second head unit and the full Nobac 5000T Twin Head meets the demands of retailers and packers for higher speeds, less downtime and quicker product changes.

Both machines benefit from:
1) Continuous operation with two labeling heads in line;
2) The ability to swap between heads to allow label reels or thermal printer ribbon to be changed on the unused head;
3) Allowing preparation in readiness for labeling the next product;
4) The option of continuous application of promotional labels, which can be achieved using a Trojan Flash labeler.

The Nobac 5000 is capable of applying linerless labels at a rate of 150 ppm and is the only fully automated sleever approved for applying Ravenwood’s linerless labels.

New Thermoform Tray

Tony and Mark decided to take full control of the food preparation and packaging process and in doing so opted for a thermoform tray sealed with MAP to replace the ‘ice cream’ style tubs. The decision to switch was largely made from an environmental perspective. The pre-formed ‘ice cream’ style tub weighed 21g whereas the thermoformed tray weighs 13g resulting in a significant saving on plastic packaging.

SUCCESS STORY

Bella and Duke has enjoyed a multitude of benefits by switching to linerless and changing the tray format.

Changing the tray format alone, has resulted in a 38% reduction in plastic packaging. The raw pet food supplier has also witnessed a massive 98% reduction in their packaging shipping costs, which has also reduced their carbon footprint.

The retailer is also reaping the rewards by taking full control of the food preparation and packaging process which as a result has eliminated the food miles associated with the transportation to and from the packer.

The c-wrap linerless label compared to the previous self-adhesive top label has improved the aesthetics of the packaging and increased the available print space. Bella and Duke’s products are of a premium standard and the packaging now reflects this.

With supply and demand constantly increasing, there was a need to drive more uptime and increase throughput. Opting for linerless along with the purchase of a Nobac 5000 linerless applicator has streamlined production and as a result, the weekly labelling capacity has increased by over 80%. Labelling speeds now run at 120 packs per minute.

Bella and Duke’s online store is now fully optimised for meeting the needs of its customers.

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January 10, 2022 - RAVENWOOD

Ravenwood's Linerless Fruit Lid Fast Becoming Label of Choice for Brand Owners, Retailers and Packers for Fresh Produce Packaging

Ravenwood’s linerless Fruit Lid is fast becoming the label of choice for brand owners, retailers and packers for their fresh produce packaging.

The Fruit Lid when applied to a carton board tray, forms a complete pack for the supply of fresh fruit and vegetable products. The food grade packaging concept replaces the need for plastic flow wrap and single use plastic bags. Subsequently, the entire pack is highly sustainable and 100% kerbside recyclable. The new fruit pack concept is generating much interest with packaging technologists around the world.

Paul Beamish, Ravenwood’s Managing Director said: “Our linerless Fruit Lid can help brand owners tackle the problems associated with single use plastic. Across a global scale, we use a horrendous amount of this material in our daily lives. Plastic has got itself a really bad name but the problem stems from how we discard it. Fortunately, efforts are now in place to tackle this problem in creating a circular economy for this material.”

The Fruit Lid is applied by Ravenwood’s Nobac 5000L linerless applicator which is designed to run and apply labels to a wide range of carton board tray sizes. Date and batch coding requirements can also be added by purchasing and integrating a Viper TIJ. Average pack speeds are around 60-65 per minute, depending on the size of the Fruit Lid, tray and products. All linerless projects, from label design concepts and tray style, right the way through to label application and launch, is handled collectively by Ravenwood and its network of printers and machinery distributors. Depending on where in the world you are located.

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November 22, 2021 - RAVENWOOD

Prep Kitchen Transforms Ready Meal Packaging with Linerless About Prep Kitchen

Prep Kitchen was established in 2016 and originally started out as a health food restaurant in Southend. Reacting to consumer demand, they started delivering healthy and freshly prepared dishes locally, direct to people’s doors. The ready meal delivery service proved to be a great success, so much so, that Prep Kitchen expanded business operations and launched an online shop. Moreover, its range of foods continue to be developed with 29 meals now tailored across each of four categories: balanced fat loss, balanced muscle gain, lower carb fat loss and lower carb muscle gain.

READY MEAL PACKAGING CHALLENGE

Poor Label Application

The success of the ready meal service was not being mirrored in the factory environment. Subsequently, Prep Kitchen was experiencing many issues with its banding machine for applying ‘strap bands’ to its product ranges. Machine downtime was a common occurrence in the factory as the banding machine was causing so much disruption. Most notably, was the slow label application and blockages in the machine were frequent, due to the strap bands creasing up when being fed through. And on changing to a new product, with a new reel of banding material, a large amount of this material was being wasted. These issues led to spending more on staffing, as the banding process is partly manual. And to add insult to injury, the finished result was a poor quality label that did not reflect the standard of Prep Kitchen’s foods. Prep Kitchen decided to seek an alternative labelling machine coupled with a different style and format of label for its ready meal packaging.

Packaging Issues

In addition to the ready meal label issue, Prep Kitchen was also having problems with its plastic ‘takeaway’ container. The lids were proving inconsistent in the application process, with some lids not fixing to the plastic tray at all. This again, lead to further frustrations and downtime in the factory. Consequently, the decision was made to source a different tray and sealing process for its range of ready meals.

THE SOLUTION

After fully researching alternative labelling methods and technologies, Prep Kitchen decided to switch to linerless for its ready meal packaging.

Nobac 5000 Applicator & Linerless Labels

Prep Kitchen purchased a Ravenwood Nobac 5000, capable of applying linerless labels at rate of 150 ppm. The Nobac 5000 linerless applicator is a fully automated linerless sleever and the only machine approved for applying Ravenwood’s linerless labels.

The Nobac 5000 applicator has also been fitted with Thermal Transfer Coders: a 53mm Falcon and 106mm Eagle. With the integration of the Coders, the printing of variable data in two separate locations on to the same label is an added functionality. With multiple recipes and SKUs, Prep Kitchen love the flexibility that the Twin Coder has to offer. The Coders boast fast print speeds and minimise downtime with the ability to change printed ingredients on various batches, quickly via the Coder interfaces. At present, Prep Kitchen is utilising the face of the label for print but there are plans to make use of the reverse, with additional product information, marketing mechanics and promotions. Due to the absence of the label liner, linerless labels benefit from double the surface print area with both sides of the label free for print.

Prep Kitchen’s labels are printed by a Ravenwood approved linerless printer:

Coveris UK

www.coveris.com

Coveris has advised both on label design and has assisted in the seamless transition from the previous method of label application to the Nobac 5000.

New Tray and Sealing Method

Ravenwood recommended machinery distributor, Versatile Packaging, based in Ireland, for the new ready meal tray, and Proseal UK to provide a tray sealing machine to seal them. Again, both the tray and sealing process outperforms the previous ‘takeaway’ tray. The Proseal sealer can seal trays at a rate of 60 ready meals per minute. The finished result also boasts a much improved presentation.

SUCCESS STORY

Switching to linerless for Prep Kitchen’s ready meal labels and changing the tray format, has completely transformed Prep Kitchen’s packaging and labelling facility. With business operations expanding, there was an urgent need to drive more uptime and increase throughput. Prep Kitchen has now fully automated its labelling processes and subsequently, reduced the number of people on the production line. As a result, this had led to an increase in line efficiency and a reduction in costly downtime, attributed to the previous labelling method.

According to Prep Kitchen’s Director, Mark Morley, the presentation of the linerless labels on pack is also unmatched when compared to strap bands. Subsequently, linerless has been rolled out to all four of Prep Kitchen’s ready meal ranges.