Denhay automates bacon packaging with Ravenwood installation

Denhay Farms has fully automated its packaging operations by integrating Ravenwood’s linerless technology for its bacon sleeves. The move has resulted in a reduction in labor and a boost in production line efficiency. The new linerless sleeves resemble traditional hand-applied sleeves but come supplied on a roll.

Founded in 1952, Denhay Farms has been producing bacon for almost 30 years. Its products are available through Tier 1 and Tier 2 retailers, as well as online platforms like Ocado and Amazon Fresh.

The bacon producer has installed two Ravenwood Nobac 5000 linerless applicators. The company has also partnered with UK-based linerless printer, ProPrint Group, to produce the new linerless sleeves.

'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 labeling operations, making it faster and more efficient, while the sleeves provide a premium, high-quality solution that perfectly complements Denhay’s brand,' said Jim Loescher, managing director of Denhay Farms.

The switch to linerless comes as part of Denhay’s efforts to reduce manpower on the packaging line, improve staff welfare and add value by smarter spending. The transition from labor-intensive hand sleeving to fully automated labeling has been implemented across all Denhay's own-label sliced bacon, including the Spoilt Pig brand and wholesale catering packs.

Denhay’s investment in two Ravenwood Nobac 5000 linerless applicators has fully optimized its production lines. These flexible applicators can sleeve a variety of fixed-weight pack formats and tray sizes, linking to weigh scales for variable weight packs and check weighing.

However, Denhay does not connect the Nobacs to scales in this application. The transition to linerless has improved packaging efficiency and reduced storage and shipping space due to the compact nature of linerless reels compared to traditional manual sleeves.

Prior to linerless, employees spent long hours performing repetitive manual sleeving tasks. Staff now have more time to focus on other areas of production, leading to improved operations and a significant boost in morale.

'The wellbeing of our staff is at the heart of our operations. This transition has been a true 'win-win' — not only have we enhanced our labeling processes, but our team is also much happier with the new system. We're so impressed with the results that we plan to expand the use of linerless technology across other products in our bacon range,' said Loescher.

Throughout the transition, Denhay sought to retain the premium look and feel of its original cardboard sleeves. Ravenwood’s linerless sleeves, supplied on a roll and cut to size by the applicator, are designed to meet these aesthetic standards. These pressure-sensitive board reels are available in slideable or non-slideable versions. With no backing paper, linerless offers an eco-friendly and sustainable alternative.

During initial trials, Denhay raised concerns over the visible white lines in the plate repeat pattern on the linerless sleeve. To resolve this, ProPrint filled the join with the same Pantone color as the sleeve border during the artwork stage, referred to as an ‘infill’. This has since become a standard offering by ProPrint Group, at no additional cost to the customer.