Denhay Farms has revolutionized its packaging operations by incorporating Ravenwood’s innovative linerless technology for its bacon sleeves. This strategic shift has led to a considerable decrease in labor requirements and a remarkable enhancement in production line efficiency. The new linerless sleeves, designed to resemble traditional hand-applied options, are conveniently supplied on a roll.
The award-winning bacon producer has successfully integrated two advanced Ravenwood Nobac 5000 linerless applicators into its operations. Additionally, the company has collaborated with ProPrint Group, a leading UK-based linerless printer, to manufacture these cutting-edge linerless sleeves.
“We’re absolutely thrilled with how seamlessly the linerless applicators and our new linerless sleeves have integrated into our production process. The machines have transformed our labelling operations, making it faster and more efficient, while the sleeves provide a premium, high-quality solution that perfectly complements Denhay’s brand,” said Jim Loescher, MD of Denhay Farms.
Transitioning to linerless packaging aligns with Denhay’s commitment to streamlining manpower on the packaging line, enhancing employee welfare, and maximizing value through smarter investments. This fully automated labelling system is now implemented across all of Denhay’s own-label sliced bacon products, including the Spoilt Pig brand and wholesale catering packs.
Denhay’s acquisition of two Ravenwood Nobac 5000 linerless applicators has fully optimized their production lines. These versatile applicators can handle a range of fixed-weight pack formats and tray sizes, linking seamlessly to weigh scales for variable weight packs and check weighing. However, Denhay has chosen not to connect the Nobacs to scales for this specific application. The transition to linerless has not only enhanced packaging efficiency but also minimized storage and shipping needs due to the compact nature of linerless reels when compared to traditional manual sleeves.
Previously, employees spent extensive hours performing repetitive manual sleeving tasks. With the shift to linerless, staff can now direct their attention to other areas of production, fostering improved operational efficiency and significantly boosting staff morale.
“The wellbeing of our staff is at the heart of our operations. This transition has been a true ‘win-win’ – not only have we enhanced our labelling processes, but our team is also much happier with the new system. We’re so impressed with the results that we plan to expand the use of linerless technology across other products in our bacon range,” said Jim Loescher.
Throughout this transition, Denhay ensured that the premium aesthetic of their original cardboard sleeves was preserved. Ravenwood’s linerless sleeves, supplied on a roll and cut to size by the applicator, are designed to uphold these visual standards. These pressure-sensitive board reels come in both slideable and non-slideable versions, offering a high-quality, seamless finish. Notably, the absence of backing paper makes the linerless solution more eco-friendly and sustainable.
During initial trials, Denhay expressed concerns about the visible white lines in the plate repeat pattern on the linerless sleeve. To address this issue, ProPrint introduced a creative solution by filling the join with the same Pantone color as the sleeve border during the artwork phase, known as an ‘infill’. This solution has now become a standard offering from ProPrint Group, ensuring the sleeves maintain a flawless, premium appearance at no additional cost to the customer.
Founded in 1952, Denhay Farms has been producing award-winning bacon for nearly 30 years. Their products are available through Tier 1 and Tier 2 retailers, as well as online platforms such as Ocado and Amazon Fresh.
For further information regarding food and drink packaging or sustainable packaging solutions, please contact Ravenwood’s marketing team at +44 (0)1284 749144.
