Famous for its iconic dispensers and playful presence, PEZ is one of the most recognisable confectionery brands in the world and has been a firm fixture on confectionery shelves for generations. Behind the colourful brand image is a highly dynamic production operation in which precision and reliability in labelling are also essential.
PEZ sweets can look back on a long history of success: they were invented in Austria in 1927. They owe their name to the word „peppermint“, as the small dragees were originally intended as refreshing peppermint sweets. In the 1950s, the company recognised the potential of the handy sweet for children. The flavours became fruitier and the legendary PEZ dispenser was developed: a milestone that made the product famous worldwide. With its combination of play, a passion for collecting and sweets, PEZ quickly became a cult brand.
1.5 million sweets per hour
Since the 1970s, PEZ has had its own subsidiary in the USA, in Orange, Connecticut, which is responsible for production and sales for the US and Canadian markets. The success of the brand in America is still characterised from there today. The US site produces more than 1.5 million sweets per hour. The packaging lines reach speeds of up to 350 rolls per minute. Both linear and transverse systems are used.
Reliable labelling plays a key role at these high production speeds. However, it became apparent at the US site that the previous labelling technology no longer met the high requirements for efficiency and accuracy. Frequent cleaning led to time losses and impaired production processes. Tony Cangiano, Maintenance Manager at PEZ, reported on the problems: „We have a very dusty, sugary environment. One of our biggest challenges was the constant maintenance and cleaning we had to do with our previous printers. We had to stop several times per shift to clean, realign and restart the print heads.“
No need for daily cleaning
PEZ was looking for a more reliable solution to reduce downtime due to cleaning, maintenance and start-up processes while ensuring consistently high print quality. Today, Leibinger printing systems take over the labelling of the variable data on PEZ products: continuously available, without the need for cleaning. „Since switching to Leibinger printers, the process has been simple: switch on, print, done. Our downtimes have been drastically reduced,“ says Gerry Figueroa, Head of Maintenance at PEZ, describing how great the improvement is in everyday life.
Unlike conventional inkjet printers, which often require daily cleaning or clog quickly, Leibinger's systems are designed to be ready for use at all times: A fully automatic nozzle sealing system keeps the nozzle airtight during downtimes. At the same time, permanent ink circulation ensures that the lines do not become blocked and that the viscosity remains stable. In the print heads at PEZ, a compressed air solution also ensures that dust and sugar from the environment cannot penetrate the system. Clean, reliable starts are possible at any time, even after long production breaks. Thanks to programmable auto-start, the printers are already in operation before the first employee enters the factory.
More efficient material management
PEZ uses the Leibinger JET2 Neo in its production. The high-performance printer is ideal for standard applications and fully fulfils PEZ's requirements for two-line printing. The low energy consumption is also impressive, and thanks to the flexible interfaces, the JET2 Neo is fully integrated into the production line.
If you would like to find out more about the solution at PEZ, Click HERE for the video.
Another advantage is the standardisation of the coding process: with the JET2 Neo, PEZ has found a printer that enables all applications with just one type of ink. This has significantly simplified warehousing and material management, while optimising the use of resources. Whether the smallest print on the individual PEZ bar or the labelling of the packaging: both processes are carried out with the same ink while maintaining the same high print quality. Thanks to the automatic nozzle closure, no solvent evaporates during production breaks, which significantly reduces consumption and maintenance costs.
The system also makes daily operation noticeably easier. The JET2 Neo can be monitored and controlled remotely via VNC (Virtual Network Connectivity). This saves travelling and reduces interruptions in the line. „We can see the printer screens on the tablets as if we were standing in front of them and can operate the printers directly,“ emphasises Cangiano.
Reliable labelling as a quality factor
For PEZ, stable labelling is directly linked to process reliability and product quality. Leibinger's systems work reliably, require minimal maintenance and integrate smoothly into the existing production lines. As a result, the efficiency of the entire system has been noticeably improved. „We would highly recommend Leibinger to other companies. It was a thoroughly positive experience for us,“ summarises Cangiano.
packaging journal 6/2025
This article was published in packaging journal 6/2025 (December).
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