Berner Food and Beverage Inc. operates three state-of-the-art facilities with more than 215,000 square feet of manufacturing and warehousing space. On average, five to six million pounds of product roll off the 24x7 production lines every month.
As a maker of perishable foods, the clock starts ticking on expiration dates—usually less than a year—as soon as products go into containers, so the company must get them labeled and shipped as quickly as possible. Additionally, Berner applies barcode labels to every case to track them through the supply chain according to the customer's specifications.
Recently, the company began packaging products in smaller pack quantities, from up to 24 or 12 eaches per case down to packs of only four, six or eight eaches per case. With the need to get more cases through the line, the company had to speed up the print-and-apply labeling process.
"Our case line rate is two to three times faster than it was before," said Troy Grove, CIO. "We had to maintain consistency and accuracy at the higher speed to avoid manual relabeling later."
At the higher speed, the current print-and-apply process missed some cases, requiring Berner to employ people to check and label missed cases manually on each line.