Reducing Costs and Increasing Efficiency with Automatic Label Applicators in Dairy Production

Dairy label automation has become increasingly critical in today’s competitive food sector. Producers juggle rapid turnarounds, stringent labelling regulations, and changing consumer expectations. Any inefficiencies can cut profits, delay shipments, and put food safety at risk. Labelling remains central to maintaining compliance and helps enhance brand visibility in the chilled aisle. From vacuum-packed wedges of cheese to yoghurt pots and cream cheese spreads, clear and accurate labels serve manufacturers and end consumers by conveying essential product details.

Labelling goes beyond simply attaching a sticker to packaging. The variety of dairy products, ranging from hard and semi-hard cheeses to softer, spoonable items like milk-based desserts, creates complex labelling requirements. Every product demands a specific packaging style, a reliable sealing method, and space for mandatory information. When a single production line handles multiple product formats, misalignment or slowdown can disrupt the entire operation.

Why Manual Labelling Falls Short

Labelling used to be a labour-intensive process involving workers affixing labels by hand. Although manual application might suit small runs or artisan producers, it quickly becomes impractical for higher volumes. In large-scale plants, slow and error-prone label placement can create bottlenecks that compromise production flow and inflate labour costs. These errors not only waste materials but can also lead to product recalls, increasing operational costs. 

By contrast, automation provides a precise, scalable alternative that ensures consistent results. Advanced systems accurately position labels at the right angle, location, and time. Modern labelling units can also integrate with printers that place real-time information like batch codes or use-by dates directly on the label material. By automating these tasks, producers can free employees to focus on more strategic duties rather than performing repetitive tasks that technology could handle.

Labelling Solutions for Different Dairy Products

Dairy packaging varies tremendously. Hard cheeses like Parmesan wedges might come vacuum-packed, while softer slices like Gouda or Tilsit often appear in modified atmosphere packs (MAP). Cream cheese spreads might be packaged in lidded trays, whereas yoghurt, kefir, and soured milk often go into pots or glass jars. To accommodate this variety, modern labelling equipment manufacturers provide multiple solutions:

Cross-Web Labellers  

Ideal for thermoformed packs, ensuring the precision of top/bottom labelling.

Often integrated into thermoforming machines, cross-web labellers place labels on the top or bottom of packages as they are formed. Vacuum or MAP (Modified Atmosphere Packaging) processes are common in dairy, helping extend shelf life. These labellers operate inline, using a compact design that conserves floor space. Through precise motion control, they apply labels accurately at high speed. Some models include press-on plates with flexible pins to conform to uneven surfaces, which is particularly important for trays with ridged lids or recessed tops.

Conveyor Belt Labellers

Handles varied pack shapes and supports zero-downtime configurations.

Conveyor belt systems label products downstream from the packaging machine. They are suitable for various pack shapes, such as tubs, trays, folding cartons, or pouches. They can position labels on surfaces like the top, bottom, or sides. A dual-track or back-to-back arrangement can handle multiple lines simultaneously, speeding up throughput without expanding a facility’s footprint. Zero-downtime configurations, featuring two dispensers per label, let one dispenser continue production while the other is replenished, preventing interruptions.

Full-Wrap Labellers

Enhances premium product appeal and acts as a tamper-evident seal.

Also known as D-labelling solutions, these wrap a label around all four sides of a pack like a band. The larger surface area accommodates detailed product information and eye-catching designs. Producers of high-end or delicatessen cheeses often opt for full-wrap labels to reinforce the brand’s premium feel. By encasing the entire pack, labels act as both an informative tool and a tamper-evident seal, assuring shoppers that the product remains intact.

Inline Labellers

Suitable for form-fill-seal machines, it ensures continuous labelling flow.

Commonly paired with vertical or horizontal form-fill-seal (FFS) machines, inline units dispense labels onto the film before the final sealing. This setup proves ideal for items like grated cheese in stand-up pouches since it prints and applies labels in one continuous flow. Inline labellers also handle round items such as Camembert by applying sealing labels that close the underside of a paper- or film-wrapped wheel.

Balancing Speed, Safety, and Shelf Life

Time is always tight in dairy processing. Whether you produce yoghurt with a one- to two-week shelf life or pasteurised whole milk lasting around a fortnight under the right conditions, any disruption risks spoiling perishable goods. Frequent product changeovers, from plain to flavoured or from one pack size to another, intensify the challenge. Here, flexible labelling technology is invaluable. Certain labellers allow quick adaptation between product types by integrating advanced controls and servo-driven systems. Operators can input the necessary speed and size parameters and run precise labelling programmes without lengthy manual resets.

Automation also safeguards product integrity through uniform, accurate labelling. Printed data like ‘best-before’ dates and batch codes must be crystal clear, so producers must consider how consumers will see this information. End users might discard crucial details if a label is only on a removable lid. Forward-thinking manufacturers now print key dates or codes on the main pack area, making them easier to spot.

Optimising Production Flow

Many factories employ a mix of packaging concepts to cater to varied consumer demands. You might have lines dedicated to large blocks of cheese sold in bulk and lines packaging single-portion dessert cups. Each line requires a tailored approach. For instance, a bottle labelling machine could label shrink-wrapped beverages, and complementary bottling equipment manages sealed containers.  Given the complexity of these lines, advanced automation systems help ensure that labelling and coding stay accurate even at peak speeds.

Ensuring Reliability in Wet and Humid Conditions

Labelling systems in dairy plants must perform reliably in humid and cold environments. Moisture-resistant materials and sealed components help maintain accuracy and durability. Certain technologies use robust components and corrosion-resistant materials. Automated feeders and dispensers also feature sealed controls to prevent water damage. In many cases, press-on, brush-on, roll-on, or blow-on applicators can function without manual intervention. This reduces the chance of human error and offers smoother, uninterrupted production runs.

Supporting Traceability and Efficient Logistics

Dairy manufacturers also face an array of traceability requirements. Secondary or tertiary packaging might need an additional sticker referencing product codes, shipping addresses, or batch numbers. Print and apply labelling (LPA) systems handle such tasks at the end of the line, applying logistical labels to boxes or pallets. Producers can track each unit from creation to the distribution centre by capturing real-time data.

When scaling up production, advanced LPA setups allow for a “zero downtime” principle: two labellers operate in tandem, so when one runs out of label stock, the other takes over seamlessly. This prevents halts that could compromise fresh goods. As a result, throughput remains consistent, and employees can focus on essential duties like quality checks.

Staying Ahead of Dairy Industry Challenges

Meeting consumer demand without sacrificing quality or safety is no small task. Producers need to remain flexible, be ready to introduce new flavours or packaging types and adapt as consumer preferences shift. In this context, labelling automation stands out as a way to smooth operations, reduce manual labour, and maintain high presentation standards. Discussing solutions with equipment specialists is often the best first step if you want to refine your processes.

Take the Next Step: Enquire About Opportunities

If you aim to overcome complex labelling hurdles and demonstrate your innovations, consider exploring an industry forum or exhibition focused on automated solutions. Professionals from all corners of dairy manufacturing and packaging convene to share new ideas, which is why a Dairytech expo enquiry can open doors to valuable partnerships. Whether you seek to exhibit or attend as a visitor, you’ll gain insights to sharpen your competitive edge and strengthen your position in a thriving market.