Initially still produced in their own restaurant kitchen, the chef and proprietor of the restaurant, Thomas Hauschild, soon moved the manufacturing process to a modern production plant in the neighbouring area. Nowadays, Zum Dorfkrug not only manufactures a number of salad dressings, it also produces a range of desserts and sauces. It’s trademark? Green and white labels. (Product image)

To ensure that the labels continued to take centre stage, the need arose to update the machinery after almost two decades of intensive production. “Due to the fact that we have our own agriculture, we also have our product quality in our own hands. To be able to offer the retail customer a perfect dessert on both a taste and visual level, we wanted to have a competent partner to support us when it came to our product packaging,” Thomas Kazmierczak, the deputy production manager explained. Zum Dorfkrug found just the right partner in the Bavarian labelling manufacturer, Gernep. Gernep was a company Zum Dorfkrug was already familiar with. The food production company had already been labelling with Gernep equipment for ten years and was very happy with its machine technology and service. However today’s demands on the labelling process cannot be compared to those of what used to be a small company and limited product range. Thus, both companies worked in close collaboration to develop a highly modern labeller that could best meet Zum Dorfkrug’s needs.

The objective was clear – the new labeller was to mainly handle pudding products and dessert sauces. The products are popular: sales have continually increased in recent years and, as a result, Zum Dorkruf is now also producing seasonal fruit jelly desserts to meet increasing demands. The hallmark of their dessert jars always was, and still remains, the green and white label. Each of the four different container shapes is decorated with three labels, as always: a front, back and lid label with tamper-evident seal. Gernep’s solution for this was a Soluta 9-1080 7SK SD with seven self-adhesive label dispensers and a nominal speed of 6,000 containers per hour. (Photo) The sophisticated machine is equipped with a non-stop function to ensure a smooth production process without long downtimes due to conversions. With the non-stop function, if a label reel runs empty, a second labelling station is automatically triggered. This is why the labeller is also equipped with seven dispensers: four labelling stations for the front and back labels, and two labelling stations for the U-shaped tamper-evident seal. The seventh labelling station for a folded label is needed for special production units and, as a result, does not have a non-stop function. The decision to use self-adhesive labels was made after careful consideration. For, in line with company philosophy, Zum Dorfkrug products are intended to be used sustainably. On the website, you can find consumer tips and tricks on how to create lanterns, plant pots or vases. Self-adhesive labels are thus the ideal choice as they can be easily removed from the container without leaving any residue.

Efficient production with modern technology

The contract presented Gernep with a real challenge. Zum Dorfkrug’s highly mechanized production site required a similarly modern labeller with its own customised auxiliary units. The integration of the self-adhesive labellers for tamper-evident seals and folded labels required special adjustments to the machine guards in order to meet the high safety standards. This resulted in a special machine structure that was not at all commonplace for Gernep.

However, for Zum Dorfkrug, the label also plays a significant role in the marketing of their products. “The appealing glass packaging with our green and white labels is what gives our products their high-quality character,” explained Sarah Lischick, Public Relations Officer, with conviction. Consequently, a great deal of technology was integrated in order to guarantee precise label application.

Just before the containers leave the machine, three sensors check if each individual container has the correct number of labels. Contrast sensors for glass containers check if the container is transparent, and can therefore detect if a label is missing. Through an integrated rejection system at the end of the labeller, the faulty container is automatically rejected to ensure that is does not end up on the supermarket shelves. But there is no need to worry as this does not mean that the dessert is subsequently discarded. The labels are simply removed and the container gets another chance to shine with a perfectly positioned label. (photo)

To design the production and type change-over procedures more efficiently, the self-adhesive labellers were not only designed to include a non-stop function. Adjusting motors were also installed. This additional option means that operators can now benefit from a number of advantages, such as faster change-over times, higher reproducibility and the ability to set parameters easily in the system. The method of operation is conceivably simple: each container type is saved in the machine with its own program and can be selected at the touch of a button. The labelling stations are automatically aligned to the saved values, meaning that the operator no longer needs to manually adjust the mechanical settings for the respective container diameter and application height for the individual products on the self-adhesive label dispenser.

Clamping starwheels ensure a further increase in efficiency as they hold the containers in place throughout the entire labelling process. Benefits to you? The operators save time during type change-overs as they can be employed for the flexible change-over of multiple container sizes. However, clamping starwheels are also very important for the application of tamper-evident seals. The container must be held in place and guided precisely in the infeed clamping starwheel. Together with special bottle plates, on which the containers are precision-centred, the seals can be rolled on along the sides without any visible label misalignment. (Photos)

During the machine development, Zum Dorfkrug placed great importance on efficient labelling and included quite a few additional features on the equipment to achieve precisely this. As a result, they should now be in a position to optimally deal with any increase in demand for their products.

Hand in hand to achieve success

The many years of collaboration already enjoyed between Gernep and Zum Dorfkrug also had a positive impact during the commissioning of such a complex machine. For product reasons, there was only a small time frame available for machine adjustment. However, thanks to the trained service engineers, it was possible to integrate the new labeller in the bottling line in practically no time at all. For Gernep, this was a special project – not only because it is always rewarding to support a family-run company with sustainable products, but also because, from a design viewpoint, this is an exceptional labeller with many technical highlights. “We are really pleased that Zum Dorfkrug once again put its trust in us to work with them in achieving this extensive project,” said Thomas Wieg, the sales manager responsible. For this food production company, the commissioning of the new label was one more step to complement the highly modern production site and continue supplying consumers with a product which is perfect in every way.