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Ice cream maker melts label inventory

Nutrition labeling requirements threatened to throw a real wrench in the works at one family-owned dairy. Thermal-transfer printing on-site was the answer.

Variable information is printed as needed by the thermal-transfer printer (above). Charlap?s uses one size label for quarts and
Variable information is printed as needed by the thermal-transfer printer (above). Charlap?s uses one size label for quarts and

On-site, thermal-transfer printing of pressure-sensitive paper labels is proving to be an ideal solution to what could have been an inventory nightmare at Charlap's Dairy.

Based in Hamburg, NY, this family-owned and operated dairy products producer packs 40 different flavors of ice cream. The only printing or package identification on the 1-qt and 1/2-gal tubs is on the lid.

Until recently, the company ordered a single lid. It was preprinted with "Vanilla" as the flavor as well as company name and address. To use the lid for a flavor other than vanilla, the company simply overlabeled the lid with a p-s label printed with the appropriate flavor. While this system worked, says company president Henry Charlap, it left plenty of room for improvement.

"I wanted to keep about five thousand labels in inventory for each flavor, so that meant managing two hundred thousand labels in inventory," says Charlap. The company managed to do this efficiently enough, until Congress passed the Nutrition Labeling and Education Act in the early '90s. Because it required a printed breakdown of the calories, cholesterol, dietary fiber content and so on for each of Charlap's ice cream varieties, something had to change in the company's carton decorating scheme.

And change it did when Charlap's installed a thermal-transfer printer from Diagraph (St. Louis, MO). The LPT/1050 Series printer enables Charlap's to print its own flavor-specific labels on-site. Operators then apply the labels to the lids by hand. Supplied by Paper Distributors Inc. (Buffalo, NY), lids and tubs are manufactured by Berry Plastics (Evansville, IN). Lids are injection-molded of linear low-density polyethylene. Tubs are injection-molded from high-density PE.

One necessary step prior to the implementation of the new labeling approach was a call to all ingredient suppliers. "I told each one that I needed the nutrition facts for their particular ingredient," says Charlap. That information was then entered into the software that helps drive the LPT/1050 printer.

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