Unilever Finds Perfect Pallet Solution with Unilev

Unilever has successfully updated the Pallet Labelling hardware and software systems at the Unilever Ice Cream factory in Gloucester. Over the years, MARKEM has supplied the plant with Cimjet ‘print and apply’ case labellers, SmartLase laser coders, and a networking system to manage the coding and labelling operations. So when Unilever decided to install new pallet labellers on its production lines linked to its existing process control systems, the company turned to MARKEM for help.

Paul Burton, national key account manager for MARKEM UK, said: “Unilever Gloucester uses a unique process control system in conjunction with a standard ERP system (SAP) to manage its production orders, and therefore needed a new software solution which could integrate with both systems. The existing software they had in place had initially been effective but it was showing limitations as the company developed.”

To give Unilever the flexibility it needed, MARKEM recommended installing the modular based CoLOS™ software platform.

Paul added: “Unilever can add to the software package as the company moves into other areas. For example, RFID tagging is not currently required at the site, but the management is aware that this might be needed in the future. When this happens, we can simply add this module to their existing software without the need to completely re-write the system.”

The CoLOS solution proposed by MARKEM also records all pallet labels for traceability purposes, and ensures that the correct labels are produced for the correct product.

To do this, CoLOS retrieves the product information from the ERP system and integrates with the process control system. It then sends this information to the Cimpak which prints and applies the labels. The information on the label is then verified by an automated scanner which reads the barcodes and checks that it is correct. In the event of an error, the line is halted and the operator alerted. Verified data is stored in the CoLOS database, and easily retrieved whenever required. The information is also sent back to the ERP system so that production records are immediately updated.

To demonstrate the proposed complete solution to the production managers at the Gloucester site, MARKEM took the team to a Unilever factory in Holland, where Cimpak pallet labellers and CoLOS operator software was already installed. Following the visit, Unilever Gloucester commissioned MARKEM to write a process analysis and design specification which would demonstrate how the complete system would operate from a technical perspective.

Once the specification had been studied and approved, MARKEM invited the production team to its Solution Centre in Belgium for the factory acceptance test – evaluating the application prototype.

The Cimpak labellers – installed in a special cabinet within the freezing area - and CoLOS pallet solution are now in use, and have given Unilever Gloucester a reliable, highly effective system that seamlessly integrates with the company’s process control systems in order to give full visibility of all pallets produced.

Kevin Lawrence, auto-palletising manager for Unilever Gloucester, said: “After looking at the other suppliers in the marketplace, MARKEM was an obvious choice for us given the history they had with Unilever. Not only are MARKEM’s products of the highest quality, the team there completely understands Unilever and how our company operates.

“We now have an excellent system which ensures the correct label is on the correct pallet, has increased our productivity and has added benefits such as a commonality of spare parts with Cimpak and Cimjet.”

Chris Robinson, IT manager, said: “MARKEM is well represented at Unilever sites across Europe so when we were considering updating the software, we knew they could deliver a proven solution”.

“Importantly, the software can grow as the company grows and we can add to the system as and when we need to without having to review the entire solution.”

Unilever Finds Perfect Pallet Solution with Unilever