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CJB Bagging cuts downtime and costs by two thirds

Supplier: insignia
08 February, 2012

Leading aggregates packer and distributor CJB Bagging, part of Day Group, has achieved cost and time savings of 66 per cent at its Tolworth site thanks to the installation of three Domino V300+ thermal transfer overlay (TTO) printers.

Founded over twenty years ago, CJB Bagging packages aggregates including salt, limestone, ballast and sand, and distributes them to a number of big name building outlets and smaller independent merchants nationwide.

At its Tolworth facility, one of three sites that CJB Bagging operates across the country, aggregates are received in bulk via its own dedicated railway line, and then offloaded into loading bays before joining one of three automated packaging lines. Here, the product is sorted, weighed, bagged and coded with a product name. The bags are then palletised and distributed by the company's dedicated fleet of delivery vehicles across the country.

Due to the heavy duty nature and dusty conditions within its Webster Griffin bagging line, the CJB Bagging was experiencing constant failure of its existing coding printer, which couldn't cope with the extreme environment. This resulted in regular, unscheduled maintenance downtime due to a combination of dust particles causing a malfunction of the printers and the print heads wearing down too quickly. This lack of reliability of the old coding machines significantly disrupted the company's ability to deliver product at peak times.

"With the increased incidents of prolonged snowy and icy conditions that we've been having over the last few years, we have seen a significant rise in seasonal demand for our products, especially in our de-icing salt alone, which we sold 5,000 tonnes of last year," Trevor Croft, site manager at CJB Bagging's Tolworth site said.

"We therefore realised that we really needed a durable coding printer that would deliver quality print, withstand the harsh packaging environment, operate at greater speeds and crucially, not let us down during peak demand.

"We started to research alternative products on the market and were extremely impressed by the build quality, performance and output speed of Domino's V300+ printers.

"As a result of working with the Domino team and undertaking a series of successful trials, it was clear that Domino's V300+ printers could withstand the challenging conditions of its packing line and meet the increased production speeds that CJB Bagging were looking for. The company therefore purchased three V300+printers: two V300+ two inch printers and one V300+ five inch printer - to code the product names onto the bags of aggregates."

The V300+ TTO printer fulfils wide area print requirements on continuous or intermittent multi lane flexible packaging machines.

Offering clean, durable and low maintenance overprinting of 300dpi data including text, bar codes, Data Matrix codes and logos, it is easy to install either vertically or horizontally on existing machines using adjustable brackets.

The unit uses simple, maintenance-free dancing arm technology providing consistent tension between new and used ribbon spools, which results in less maintenance, increased uptime and higher production speeds. Domino's patented ribbon economy system also enables users to save up to 60 per cent on ribbon usage without reducing print resolution.

"The V300+ printers now enable us to code 5,000 – 6,000 bags a day at a speed of 17 per minute, which means we can easily keep on top of customer orders even when demand reaches its peak when we experience unscheduled and extreme weather conditions," Croft said.

"In addition, because we run out lines from 7am to 5pm five days a week, as well as a half day on Saturday, we have achieved time and cost savings of a massive 66 per cent, which is fantastic."

"We are delighted with the results since installing our V300+s. The Domino support team are always on hand, so we no longer have to worry about the coding of our products, and we can concentrate on delivering our aggregates to our customers on time. In fact, we're so happy with their performance, that we are already looking to install the V300+ onto our other two bagging lines."