Denhay transforms bacon packaging with linerless technology

Denhay Farms has upgraded its packaging process by adopting Ravenwood's linerless labelling technology for its bacon products. Moving away from traditional hand-applied sleeves, the new linerless solution features pre-printed sleeves supplied on rolls, streamlining production and reducing manual labour.

The Dorset-based bacon producer has invested in two Ravenwood Nobac 5000 applicators to automate the application of its bacon sleeves. These machines are now operating across Denhay’s entire range, including own-label sliced bacon lines, the Spoilt Pig brand, and catering packs. The change is designed to improve efficiency, reduce workforce demands on the packaging line, and lower operational costs.

The Ravenwood Nobac 5000 applicators offer flexibility in handling various pack sizes and formats. Though capable of integrating with weigh scales for variable weight products, Denhay is using the machines for fixed-weight packs without scale connection. Additionally, the move to linerless sleeves has optimised storage and transport, as linerless reels require less space compared to conventional sleeves.

To produce the new sleeves, Denhay has partnered with UK-based printer ProPrint Group. An important consideration in the transition was retaining the premium appearance of Denhay’s original packaging. The linerless sleeves, cut to size during application, deliver a seamless, high-quality finish. They are available in both slideable and non-slideable formats and, without a release liner, offer an environmentally friendly alternative to traditional labelling methods.

Jim Loescher, MD of Denhay Farms, said: 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.

During initial trials, Denhay encountered challenges with visible white lines on the repeat pattern of the sleeve design. Working closely with ProPrint, a solution was developed using a border infill technique to match the Pantone colour of the sleeve, eliminating the issue and ensuring a consistent look.

The introduction of automated linerless labelling has also benefited staff welfare. The reduction in manual sleeving tasks has allowed employees to focus on other production areas, leading to improved morale and greater operational efficiency.

This article was originally published by Ravenwood Packaging.