A continuous inkjet beer success: from low contrast to enhanced performance
Every coding challenge is different
Yet another conversation with one of our sales representatives the other day, and he shared several hands-on stories that reinforced a simple lesson: every customer is different, and every coding challenge calls for the right combination of technology, ink, and expertise.
The challenge: clear codes on colored glass
The issue was code visibility. The black inks used with the existing continuous inkjet coder were not providing enough contrast on green and dark-brown glass bottles.
For a returnable-bottle operation, however, visibility was only one part of the challenge. The codes needed to remain readable after ice-bucket use and refrigerated storage. At the same time, they needed to be removable when bottles returned to the factory for cleaning, refilling, and resale.
All of this had to happen at a line speed of 45,000 bottles per hour, while maintaining consistent code quality despite the extremely high temperatures routinely experienced in the factory.
The solution: white, alkali-soluble ink
The solution was a white, alkali-soluble ink paired with the 9750 Expert+ coder. During a two-month trial, the white, high-contrast markings proved easier to read on colored glass than the previous black codes.
They also stood up to in-market use and storage, while remaining easy to remove when required.
The pigmented white ink was also compared with a yellow ink tested by the bottler. The white code delivered higher contrast and could be erased using a lower percentage of caustic soda. This mattered because it supported both code legibility in the market and efficient bottle cleaning during the return process.
Reducing total cost of ownership
The coding solution also addressed total cost of ownership. Unlike the existing system, the 9750 Expert+ coder does not require ink modules to be replaced twice a year.
With Intelli’Swap®, replacement intervals are synchronized, allowing individual items to be exchanged instead of entire blocks. This helps reduce maintenance requirements and overall operating costs.
Flexibility for multiple production lines
Flexibility was another important consideration. A single-point, 24-pin connector made it quick and secure to move the high-speed coder between lines.
In addition, the coder’s hybrid ink circuit can run either dye-based or pigmented inks. This gave the bottler the ability to use one model across multiple applications, including non-pigmented black inks for transparent bottles, while reducing the need to hold additional spare-parts inventory.
A solution designed for the future
The result was a cost-effective, high-quality solution with the flexibility to support future requirements. The bottler was sufficiently impressed to replace its existing competitor coders with this configuration.
Stories like this show why coding is never simply about printing a mark on a package. With continuous inkjet technology, the right answer depends on the substrate, the environment, line speed, durability requirements, and the operational realities behind the line.
Above and beyond, our sales representatives know more than anyone how to find the right solution for every coding challenge.
