Chocolat Frey is the market leader among Swiss chocolate manufacturers and lives up to its slogan „on everyone's lips“. When it was time to update its labelling technology, the company brought REA JET on board, an experienced partner that has established itself worldwide as a specialist in industrial labelling systems.
The company, which is part of the Migros Group, was founded in 1887 and has been successfully combining tradition and modernity for more than 125 years. The confectionery department produces, packs and palletises chocolates and bars. It has a market share of 37 per cent. REA JET HR thermal inkjet printers were recently integrated into two of the production lines. They label tubular bags with the best-before date and a production code that enables the goods to be traced.
In line with demand, the plant runs in three shifts around the clock. Around 31,500 chocolate bars of different sizes of the „Branche“ variety are produced per hour and individually wrapped in the previously labelled film. With a 35 ml ink cartridge, around 450,000 bars can be labelled with optimised resolution and an adapted degree of blackness.
Complex specifications
The High production speed is a challenge because the print has to dry at record speed and adhere well to the film, as a sharp-edged moulded shoulder for rounding the packaging follows just one metre after the marking. REA JET ink is the perfect solution for this demanding task. „Multiple Black“ which was specially developed for non-absorbent, smooth surfaces. Over 30 years of experience have borne fruit here.
The excellent resolution of up to 600 dpi combined with high optical density, brilliant blackness, excellent contrast and unique edge definition make them ideal for coding goods. This enables seamless mapping of the entire production and logistics chain and promotes automation. The aim is to increase efficiency, quality assurance and reduce costs in all areas.
Clean thing
In combination with the thermal inkjet printer, the ink enables hygienic, solvent-free, environmentally friendly labelling of packaging and is therefore ideal for the food and pharmaceutical industries. The goods are protected from flavour-altering emissions, which benefits the flavour of the chocolate. Thanks to the No use of solvents fire risk and storage security costs can also be significantly reduced.
The smudge-proof, high-resolution labelling is extremely legible and allows comprehensive product declarations in accordance with the requirements of the new EU Food Information Regulation. Thanks to maintenance-free HP technology, a new print head is available every time the cartridge is replaced, eliminating the usual follow-up costs for service and spare parts. These features make the REA JET HR a clean and safe alternative to many continuous inkjet systems (CIJ).
Chocolat Frey, which previously implemented CIJ modules that proved to be very susceptible to faults, is also convinced of this. The disadvantages included numerous system downtimes and a lengthy procedure for interrupting production and restarting the systems after long periods of downtime. Added to this was the contamination of the environment as well as the odours and health hazards caused by evaporating solvents.
Modern solution
As the CIJ modules were getting on in years, Chocolat Frey took the opportunity to look around for modern labelling technology. After a demonstration, the decision was made to install REA JET systems on a trial basis. The operating staff took the opportunity to put them through their paces and quickly decided in favour of adopting them.
The new system fulfils all requirements and is also easy to use. It can be controlled either via PC or tablet or on site via the display. The user menu impresses with simple user guidance and is easy to understand. Modern interfaces enable network integration and simple connection to ERP systems and databases. There is complete freedom of design when creating text, graphics and characters. Print jobs can be entered, changed, saved and retrieved quickly.
After the trouble-free test phase the REA JET solution was finally integrated in just eight hours. The compact design favoured the smooth integration of the components into the production line. True-type fonts, XML file format, Unicode and communication via Ethernet, among other things, ensure problem-free configuration and networking in line with the requirements of Industry 4.0.
High process reliability
REA JET relies on Sustainability and Quality, develops and produces all products itself. The full-service provider can supply hardware, software and consumables and realise customer-specific solutions. Chocolat Frey also benefits from the company's global service and sales network and appreciates the proximity to the Swiss subsidiary in Hirschthal, Aargau. There are therefore plans to use further REA JET systems in the future.
