Labeling Innovations from Weber

Food labeling doesn't need to be hard.

When you put a label on your food product, there are many requirements to have it be successful

The label has to be accurately applied. Plus you need it to convey your message or the packaging requirements for your industry, and it should last the lifetime of your product. 

Food packaging comes in an ever-increasing array of containers and design shapes. This can be a challenge for small to medium companies with limited resources. Many times manufacturers are applying labels by hand which is very time-consuming and costly. But now there are automatic labeling systems of all sizes and types that can not only label just about any type of container, but they also are quite cost-effective.

Let's explore some of the many different styles of food packaging now available.

Food Containers and Labeling Recommendations

Top and/or Bottom Labeling

A label is applied to the top, bottom or multiple sides of a product. This is one of the most common container shapes. It can be a box, clamshell, shrink-wrapped, pouch or any other flat-sided product where a label can be wiped onto the surface. Sometimes products are required to have a label on top for identification/marketing purposes and will need another label on the bottom with ingredient or nutritional facts.

Label Materials:  Weber offers a variety of labels to meet the demands of food packaging. Each material is selected to endure a wide range of environmental extremes from refrigerated to freezer/wet and humid storage. Plain paper labels work well for temporary labels while longer term labels need to be more durable like a BOPP or paper with a lamination for protection.

Labeling Systems: Depending on the required line speed, the Alpha HSM works great for one sided labeling, usually top-down. It can also be laid on its side to label sides of products. The HSM is a modular label applicator capable of high labeling speeds in a wide variety of optional sizes. The powered unwind and rewind keep the HSM labeling accurately and consistently at all times.

The Alpha Compact is a more economical version of a topside or bottom-apply label applicator. It is easy to operate and has a smaller footprint to fit tight spaces. Perfect for first-time labeling system users.

And the Pack Leader 211D is the right label applicator to use for top/bottom labeling. It comes with two ELF-20 label applicators mounted opposite each other on a built-in conveyor. This system allows you to label both top and bottom of a container in one pass.

And when you need date coding, Weber can supply their Markoprint X1-Jet inkjet coders. The system can mount right on your label applicator and uses convenient HP ink cartridges for no-mass coding. 

Wrap-Around Bottle Labeling

A label is wrapped around a straight-sided container like a bottle, jar or cylinder. Food containers for sauces, oils, salad dressings, and more can be labeled accurately and quickly at up to 40 products or more per minute. If your container has a taper, that can be handled with a different applicator that angles the label (see Tapered Container Labeling below.)

Label Materials:  You can use a variety of labels to label your round container depending on the usage and storage. When picking a material, think about how durable the label needs to be. If the container holds oils, sauces or something that might stain or make the ink run on the label, you should use a gloss or matte laminate for protection. Plain paper labels work well for temporary labels while longer term labels need to be more durable like a BOPP or paper with a lamination for protection.

Labeling Systems: Most labeling systems are chosen by the label size and line speed needed. If you are labeling small containers with labels under 4" tall, the Pack Leader ELF-50 is a very economical solution. The ELF-50 is a portable tabletop unit that can be moved into production when needed. These are usually used with hand-fed production but you could connect to an automated line as long as you keep it to about 25-30 products per minute depending on product size.

When you need to go faster and perhaps use a larger label, the Pack Leader PL-501 is the choice. You can use labels up to 6" tall and apply them at speeds up to 40-50 products per minute. It is super reliable and easy to set up. The PL-501 is a staple in many food and beverage companies.

When you have a food production line that is all about speed, the Pack Leader PRO-625 can help you label at up to 130'/minute. The PRO-625 can do wrap-around labeling as well as one side and two-sided labeling of containers. The labeling heads can tilt on axis so they can be used with tapered or shaped products.

And when you need date coding, Weber can supply their Markoprint X1-Jet inkjet coders. The system can mount right on your label applicator and uses convenient HP ink cartridges for no-mass coding. 

C-Wrap (Clamshell) Labeling

Many food packaging operations are now using clamshell containers for bakery goods, pre-made meals, fresh produce, and much more. A long continuous label is applied to three sides of container. These are the standard labels used by many bakeries for clamshell labeling of cookies, doughnuts and muffins. The label is presented by the applicator and the clamshell literally runs into it. Brushes then wrap the label on top and beneath the container as it travels by. The label acts as a closure for the container. 

Label Materials:  Most times, labels used in clamshell labeling are very temporary, usually only for a day or two. Paper labels are the economical choice here. Preprinted labels can be colorful and protected with a gloss or matte varnish for added durability, especially during shipment. Laminates are not used very often as this makes the container harder to open unless the label is perforated.

Small bakeries or food companies that use clamshells might be using preprinted labels that leave room for variable data to be added by a thermal transfer printer. This is usually when a small run of labels is needed or there are frequent changes in ingredients or nutrition facts. Often times these labels are hand-applied.

Labeling Systems: The best option for a clamshell labeling system is the Pack Leader PL-211CS which is specifically designed to apply labels on three sides of a product. The PL-211CS is built for a diverse range of container sizes is fast and easy. The standard one-touch screen and label sensors make it simple to adjust for various labeling applications. And, with the manual position setting, your labels are placed accurately on the product, each and every time. 

If you need date coding, Weber can supply their Markoprint X1-Jet inkjet coders. The system can mount right on your label applicator and uses convenient HP ink cartridges for no-mass coding. 

Recessed Lid Labeling

A wide variety of today's pre-packaged foods come in clear plastic containers that have recessed lid for added strength. Foods like prepared salads, sauces, produce, spices, dips, soups and more find their way into these containers. It can sometimes be tricky to get your label automatically applied correctly as it has to reach into the recess to stick and adhere to the package. 

Label Materials:  Clear plastic containers often contain fresh products that need refrigeration or freezing.  And the labels are usually the main branding POS labels for the product. You want to make sure your labels not only look fantastic, but will stand up to the low temperatures and moist conditions found in these environments.

If your food products are dry and will be stored in room temperature, you can go with a paper label but I would recommend a lamination for durability. You want that label to keep looking great to attract a buyer's attention. 

If your products will see cold temps and moisture, I would recommend a vinyl or BOPP material that is made for cold temps and is moisture-resistant. Small quantities of either of these label types would benefit from digital label printing while larger runs of 10,000 or more would be more cost-effective being run on a flexo press.

Labeling Systems: Weber has two Alpha label applicators that work well for recessed labeling. The only real considerations are speed and price. The Alpha Compact is a more economical choice for top-down recessed labeling of these kind of containers. It has a small footprint and can label up to 164' per minute. An extended peeler plate allows the Alpha Compact to reach very close to the recess and get the label affixed.

The Alpha HSM is a modular high-speed label applicator that can apply labels up to 164 feet/minute. One of the unique features of the HSM is that you can hook up two Alpha HSM label applicators in tandem for zero downtime labeling. When one system runs out of labels, the other system automatically kicks in and seamlessly begins labeling where the other HSM left off. The powered servo drive unwind and rewinders increase labeling accuracy.

If you need date coding, Weber can supply their Markoprint X1-Jet inkjet coders. The system can mount right on your label applicator and uses convenient HP ink cartridges for no-mass coding. 

Pouch Labeling

With the invention of the stand-up pouch, suddenly many products previously packaged in boxes now have a new high-tech home. Pouches, mainly made of plastic derivatives and recyclables, are often pre-printed. But many manufacturers use a generic branded pouch and call out contents on a colorful front label, usually accompanied by an ingredients/nutrition value label on the back. Pouches need to be labeled empty, before filling unless using special equipment.

Label Materials:  Pouch labels need to have a little give so that they stretch when the pouch is filled. BOPP or vinyl film labels work best as they adhere well and adjust themselves when the pouch expands. Paper labels can be used but often run into problems if the pouches are bulging.

Label Materials:  Pouch labels have to have a little give so that they stretch when the pouch is filled. BOPP or vinyl film labels work best as they adhere well and adjust themselves when the pouch expands. Paper labels can be used but often run into problems if the pouches are bulging.

Labeling Systems: For entry-level pouch labeling, the Pack Leader ELF-20 is best. It has a small footprint and can be easily moved out of the way between packaging runs. When combined with a shuttle feeder, pouches can be automatically loaded onto the conveyor for labeling. Speeds up to 30-40/minute.

The Alpha Compact is the next choice for top-down pouch labeling. It has a small footprint and can label up to 60 pouches/minute depending on the speed of the shuttle feeder and label size. A wipe-down brush affixes the label to the pouch for better adhesion. It's easy to set-up and run.

The Alpha HSM is a modular high-speed label applicator that can apply labels up to 164 feet/minute. Combined with a high-quality shuttle feeder, this system can crank out accurately-labeled pouches quickly all day long. One of the unique features of the HSM is that you can hook up two Alpha HSM label applicators in tandem for zero downtime labeling. When one system runs out of labels, the other system automatically kicks in and seamlessly begins labeling where the other HSM left off. The powered servo drive unwind and rewinders increase labeling accuracy.

If you need date coding, Weber can supply their Markoprint X1-Jet inkjet coders. The system can mount right on your label applicator and uses convenient HP ink cartridges for no-mass coding. 

Tapered Container Labeling

Labeling tapered containers can be tricky. We have all seen and used these product that come in the little tubs, often used for dips, sauces, seasonings, dairy products, produce and more. The containers usually have a top label (see recessed labeling above) and a side label. The tricky part is the side label. Because the container is tapered, it has a smaller circumference around the bottom than the top.

For a label to lay flat correctly and look level, the printed label needs to be curved. We call it a smiley label since it looks like a smile! When put on a taped container correctly, it follows the outside shape perfectly.

Most tapered containers are labeled on top and around the side with a special "smiley" label.

The side label on a tapered container needs to have a curve to lay flat. We call them "smiley" labels.

Label Materials:  Since these labels are usually temporary, lasting 30 days or less, they can be either laminated paper labels or BOPP/film labels for more durability. Many times these containers are refrigerated so they need protection from the moisture and cold. Both types of labels work well with the plastic containers. Just be sure to get the specifications of the taper on your container and give it to your label printer as they need to match the curves for a successful match.

Labeling Systems: The Pack Leader PRO-625 is the best choice  for consistency labeling tapered containers. With the PRO-625, labeling for a diverse range of containers is fast and easy – regardless of size or shape. The standard one-button teach product and label sensors make it simple to adjust for various labeling applications. And, with the manual position setting, your labels are placed accurately on the product, each and every time.

The PRO-625 has label heads that tilt on a 12-degree x-y axis, the PRO-625 even works well for tapered or shaped products. The label count feature lets you precisely track progress at any point during the production run. Chain aligners center your product before entering top hold-down controls that keep the product in place.

Did we cover everything?

I doubt it but that should cover 95% of the containers used in the food industry today. If you have something not mentioned or would like to talk about how we can help label your food items, contact us today at info@weberpackaging.com or use the free sample offer below.

Weber Packaging Solutions has over 90 years of experience helping customers label their food products successfully. We can help you get the right labeling system, the best labels for the application, and back it with expert customer service to keep your production lines rolling.

90 Years and Just Getting Started

This year, we celebrated our 90^th anniversary–a truly momentous occasion. As we interviewed customers and employees throughout 2022 as part of the celebration, one thing became clear. Labeling excellence starts with excellent service. Whether it’s how we treat our employees, how we support our customers or the technologies we provide, at Weber, we work in service to others.

Read on to explore some of the highlights from this year’s celebration.

Our Customers Are the Best–Plain and Simple

At Weber, we don’t look at our customers like a transaction, we look at our partnership as a shared path and at our customers’ success as our own. We were thrilled to hear what some of them had to say about us!

Jeremia Steves from Boar’s Head shared, “Great folks with great solutions–plain and simple. Weber has experience within the space and does a great job of connecting customers' needs with executable solutions.”

3D International started as a humble car wash in the Van Nuys, California area back in 1980 and soon after began manufacturing their own brand of soap, degreasers and tire dressings.  As word spread, they needed to expand the production of their quality automotive products and dedicate themselves to just manufacturing.

With over two decades of research and development, 3D has established a solid name in the car care products industry for car washes, detailers, and car dealerships.

In 2014, 3D built a new facility in Santa Clarita where they moved into creating new  polishing compounds and car-care soaps along with their degreasers and tire dressings. As their fame continued to grow, they expanded, adding new filling and packaging lines to keep up with demand. The 3D International factory headquarters includes a 70,000 square-foot warehouse with computerized mixing, high-speed production and strict quality control.

The company’s Production Manager, Genaro Levy, took some time to tell us about the growth at 3D International and how they are handling their success.

“We were famous for our soaps, tire dressings and degreasers, but since 2010, we have pursued the development of polishing compounds for automotive finishes,” said Gernaro. “3D now has compounds that are unmatched in how fast they polish. This one-step compound polishes (removes swirl marks), protects (adds a protective film), and leaves a great shine.”

The company now produces about 150 different products in a range of containers including 2 oz., 8 oz., 16 oz., 24 oz., 32 oz., 1 gallon, 5 gallons, 55 gallons, and 275 gallon totes! Over 95% of their products are biodegradable and/or green with 100% VOC compliance.

Whether you are looking at label automation for the first time or if you are getting ready to update some old label printer-applicators that have worn out their welcome, there are a few important things to think about. 

Make sure you have all the information you need to make a decision that will reward you for years to come.

There are quite a few different varieties and manufacturers of print-apply systems out there. Most work well, as advertised.

But there are some major differences in the features and construction of these systems that can effect production up-time, maintenance and longevity.

Some Common Issues

 Durability

Depending on your type of product and the production line that the print-apply system is used on, it can see modest to over-whelming activity. First time automation companies might just be labeling 10-20 pieces an hour, where a distribution center might be labeling a package every few seconds.

But in both cases, durability is a major consideration. What would happen if the machine failed? Can you have your production line down for any length of time while the system is fixed? This could create a bottle-neck that keeps products from going out the door. You can employ a zero-downtime system that has a back-up printer-applicator, but that can get expensive. 

When looking for a new print-apply system, see who has a proven track record of durable systems with a good maintenance track record. As with anything, you get what you pay for. Buying a cheap system will only bring future headaches as well as a pain in your wallet when you have to replace it too soon.

Check out systems that are built using substantial materials like stainless steel and aluminum plate. Check and see if all the connections are protected from damage or abuse. Are moving parts like applicator arms shielded to protect the operator or local workers? Make sure the print engine that you chose is a new model from a major manufacturer like Zebra or Sato with up-to-date features. These integrate easily with your online systems for loading label formats and monitoring jobs. 

“It’s all about the community and how we bring people together through beer,” said co-founder and Master Brewer Deb Loch.

Celebrating their fourth anniversary in business, Deb and co-founder Jill Pavlak have been slowly building their brewery through quality products and local participation. Urban Growler (www.urbangrowlerbrewing.com) was opened in July 2014 when Deb and Jill combined their talents and passion to create outstanding beer, food and a welcoming space for the community.

And their brand tag line says it all: “We’re Beer For You!”

As Minnesota’s first female-owned brewery, they had many challenges getting their vision in place. But with the help of friends, family and even total strangers, Urban Growler became a reality. Their patrons believed in the founders vision and their support helped get one of the hottest new breweries off the ground. Now that spirit is being repaid with a company that is there for the community.

The brewery, located at 2325 Endicott St. in St. Paul, Minnesota, features a warm, welcoming taproom, on-location kitchen and an outdoor beer garden. There are also indoor retail spaces that can be rented for hosting meetings, weddings, and local social gatherings.

But one of the most interesting things about Urban Growler is the building itself. This century-old brick and timber space was once home to the St. Paul Police horse stables back in the late 1800’s. After that tenure, it became a manufacturing facility for wooden skis and hockey sticks (after all, this IS Minnesota) as well as other warehousing in later years. The designers for Urban Growler did an awesome job of resurrecting the true character of the old building while adding a few modern updates for comfort and accessibility.

The brewery is looking to output 2000 barrels this year, up from about 1250 last year. Their flagship brews include traditional beers like their CowBell Cream Ale, Midwest IPA and their De-Lovely Porter. They also brew an interesting Kentucky Uncommon Ale and a “West-Coast-hops-meets-East-Coast-maltiness” Golden Hammer IPA. All Urban Growler flagship beers are lovingly handcrafted in 10-barrel batches under the close supervision of Master Brewer Deb.

But one of the best things about being a small brewery is that you can brew small batches and experiment with limited releases. Last year, Urban Growler brewed over 40 different beers, some as small as half-barrel experiments! Most of these end up in the taproom where their popularity is voted on by their customers’ consumption. The more popular winners then might end up as a seasonal or limited release for distribution in cans.

Lately much of their focus has been on a concept that they call “Plow to Pint®”. They have found that people would rather drink locally and that they appreciate locally sourced products. For this endeavor, Urban Growler uses ingredients harvested from farmers in the area to create unique beers with a distinct twist. Some of the recent favorites include Blueberry Wheat featuring blueberries harvested from a family-owned farm in Princeton, MN, and an Oak Aged Imperial Ale with Frontenac Grapes that used classic oak barrels and Frontenac grapes gown outside Red Wing, MN. They are currently working with the Rainforest Alliance in Guatemala and the University of Minnesota to create a collaboration brew using the sustainable ramon nut. Not your ordinary Stout.

While most of the flagship beers at Urban Growler are filled by a Wild Goose system into preprinted cans bought in bulk, these new small batch creations are getting canned and labeled using pressure-sensitive custom-designed labels. This allows the brewery to be more flexibile while doing a small batch economically and using eye-catching designs for their new brews.

Urban Growler has been canning approximately 150 cases of their small batch seasonals every few months. But because of their success, they are now looking to ramp things up to 250-case batches of their special beers once a month. To do this, the brewery had to invest in a new automated labeling system.

After much research and a few false starts, they happened to find Weber Packaging Solutions online. They contacted Weber whose local rep came out to see what the best solution would be for Urban Growler. The brewery was growing and would need to be able to scale up to the larger brew runs at higher speeds in the future. Reliability was key to a new system and it had to be easy for the staff to operate.

I can honestly say that, in more than 35  years in the packaging industry, I have never seen such a diverse and rapidly growing market as the current surge in cannabis sales.

As more and more states legalize the sale of both medical and recreational marijuana, the marketplace has exploded with  new products covering just about every vertical market. There are cannabis beverages, edibles of all sorts, oils, lotions, candles, clothing, and, of course, the dried flowers for smoking.

The cannabis industry is exponentially growing with a forecast of $24.5 billion in sales by 2020. That's just a year and half away. As an example of state income, Colorado sales for combined recreational and medical for April 2018 was $124 million dollars. Just a one month total in a state of 5.6 million people.

The packaging requirements are varied by state and often can conflict with each other. Child-proof packaging is required in most states, for example, and Colorado allows child-proof resealable zipper bags but Washington state does not. Some states require single-use packaging even for large quantity items. And edible food products that might be mistaken for non-cannabis products need to have the THC symbol coded onto the product with edible ink in Colorado. These are just a few examples of the range of hoops that manufacturers have to jump through.

Branding has become a focus of the cannabis packaging, especially with products that are trying to attract more affluent buyers willing to pay a premium for products. Up-scale packaging designs are appearing to improve the reputation of cannabis products.  But the US Trademark Office (federal government) denies trademark protection to cannabis brands making it difficult to clearly protect your identity.