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Pharmaceutical Manufacturing and Packing Sourcer
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Warehouse logistics is one of the most sensitive areas of a company, and
any errors in the processes here can cause significant losses. In fact,
recent research shows that distribution centres are losing an average
of nearly £242,000 per year, simply due to mis-picks. But another
critical factor arises from the temperatures to which goods are exposed:
frozen storage is a growing issue.
Freezing temperatures of
-30°C not only affect the stored goods, but the materials used in
logistics too. Mobile computers, scanners, printers and voice solutions
must therefore demonstrate exceptional resistance.
Cold Conditions
Frost,
condensation and cold air all create individual challenges for rugged
mobile computing equipment. The insulation used to keep refrigerated and
frozen storage areas cold also poses problems when it comes to wireless
connectivity. Here follows a brief overview of how these conditions
impact mobile computer performance.
Frost
Liquid-crystal
display screens can become obscured by frost, preventing users from
seeing prompts or verifying the data they enter. This means that
productivity and accuracy both suffer. In addition, barcode readers and
image capture devices will not function if frost covers their optical
ports. In these cases, workers must resort to manual data entry, which
severely reduces productivity and increases error rates.
Condensation
This
raises the same problems as frost by obscuring screens and causing
scanners to fail, but presents a more serious issue because it can occur
inside the screen or scan window – and thus cannot be cleared away
easily. Condensation can result in internal components to corrode,
short-circuit and fail, making devices unusable until they are repaired
or replaced.
Cold Air
Battery-powered mobile devices
are challenged by cold air because batteries cannot release their energy
when temperatures drop below certain levels. The result is reliability
and productivity issues that threaten on-time performance and reduce
overall efficiency. Additionally, radio waves travel differently through
cold, damp air than they do in warmer, drier conditions, so users may
experience less range throughput from their wireless local area network
systems unless adjustments are made.
Device Placement
So
why not simply place devices outside of cold storage? This is a
question that is often contemplated. But the problem with this approach
is that it drastically decreases pick rate and staff efficiency levels
due to the added distance travelled by workers.
Improving the
‘chill factor’ of devices is therefore imperative to any warehouse
integrating cold storage. The capability of the printer media, in
particular, is often underestimated, but is crucial for a smooth process
flow. For example, faded or smudged ink, detached labels and illegible
receipts reduce efficiency and productivity levels because it is
time-consuming and expensive to identify individual goods and reprint
individual labels.
Printer Media
All consumables
related to the printer process can be referred to as printer media. In
addition to barcode labels and radio-frequency identification (RFID)
tags, this also includes receipts, tickets and ink ribbons.
In
logistics, a distinction is made between traditional standard media and
special labels. Special labels include, for example, RFID labels,
wristbands for hospitals and durable labels.
A differentiation
is also made between media with short-term resistance, used
predominantly in parcel shipments, through to very resistant labels that
withstand the effects of chemicals or temperature – often used in
laboratories. Hence, it is critical that companies choose a provider
with the widest possible portfolio and varied experience, in order to
identify the best solution for a given application. Ideally, the
manufacturer should be able to offer a complete solution from one single
source, including printers, labels and, where applicable, ink ribbons.
Either
thermal direct or thermal transfer labels are used for labelling and
marking products, depending on the application and requirements. In
short, obtaining a perfect match between label and printer is crucial
across all environments.
Proving Durability
Of
course, even the most durable components cannot ensure that a mobile
computer is rugged enough to stand up to real-world use. Extensive
testing is necessary to prove that a design has what it takes.
Mobile
computer manufacturers looking to achieve industrial-grade durability
must establish standards for impact and temperature resistance – then
test to ensure the standards are met. While these assessments are often
performed by the manufacturers themselves, testing to the International
Electrotechnical Commission’s International Protection (IP) standards
for dust and water resistance must be performed and certified by
independent labs.
Most industrial-grade mobile computers are
rated IP64, with the 6 indicating that the device is dust-tight, and the
4 indicating it will resist being splashed or sprayed with water.
Companies should ensure that their hardware meets these specifications
before subjecting it to the cold store.
Another area to consider
is product features: large keys are better for gloved hands, for
example. And the brighter the defroster screen, the easier workers can
go from outdoor dock to dark freezer without condensation.
Good Balance
Here
are five tips to ensure your warehouse is able to achieve the right
marriage between printers, devices and labels in the cold store:
1. Operating Environment
The
environment in which the media will be used has a direct impact on
every single component of the printing process. Temperature plays a
crucial role as the individual elements involved need to be of a
specific composition, depending on the level of cold.
This is
especially true if the temperature to which the printer media are
exposed is subject to fluctuations. For production facilities where
chemicals are processed, it is important to choose materials for the
media that will not react with the chemicals.
In selecting the
right provider for the purchase of printer media, the customer and a
representative of the manufacturer should accurately evaluate the
operating environment so that a customised solution can be created.
2. Selecting the Best Provider
To
identify the most appropriate media for your application environment, a
thorough analysis is required to find the right combination of
necessary components. Detailed expert advice is essential in this
respect, especially for critical applications.
Ideally,
following in-depth analysis, the provider will be able to test the
recommended solution in a laboratory environment prior to
implementation. After that, the customer should always receive a bespoke
offer to meet their individual needs.
3. Choosing an Adhesive
The
adhesive is crucial for efficiency and for getting the best out of the
printer medium. Due to the wide variety of substrates (such as dry/wet,
flat/curved, smooth/rough, clean/dirty, hot/cold or painted/rusted) and
external influences (temperature, humidity and sunlight), the demands on
the adhesive must be closely examined and taken into account in order
to make the right choice. After all, the composition of the adhesive and
binder determines whether the medium adheres well or is easily
detachable.
This is especially true for the particularly
sensitive area of frozen storage because extreme temperatures as low as
-30°C are not uncommon. In such cases, the media must also demonstrate
frost resistance. Each storage environment and application requires a
particular combination, and the customer will need to find the perfect
match.
4. Thermal Transfer Printing
Obtaining an
optimal match between labels and ink ribbons is important for the
thermal transfer printing of media. It is crucial to assess what demands
the customer will be placing on the printed label.
In frozen
storage, thermal transfer printing must be able to withstand temperature
fluctuations of up to 40°C. Labels must adhere reliably under these
conditions, yet be easy to remove at any time.
In this kind of
environment, companies need to be able to rely on the supply quality of
their provider, especially when it comes to high label volumes, in order
to ensure accurate and reliable operation and, thus, a good level of
productivity in the warehouse.
Factors such as scratch and
abrasion resistance, as well as resistance to temperature, chemicals and
humidity, must also be taken into account. In general, the harsher and
more challenging the operating environment, the more rugged and flexible
the media must be.
5. Single Source
Ideally,
companies will select their warehouse solutions from a single source,
purchasing both hardware and media from the same provider. This way,
customers can be sure the device, labels and/or ink ribbons are
perfectly matched.
It is even better if the provider can offer
other services too, such as a printhead replacement scheme. Receiving
free replacement of parts that wear quickly is a great way to ensure a
higher level of productivity and efficiency, resulting in a rapid return
on investment.
Furthermore, in the event of system failure, the
cause can be found quicker when the products used, including printers,
computers, scanners, imagers and labels, all come from a single source.
Problems are easier to identify, or often do not even arise in the first
place, because systems are harmoniously integrated.
Choose Wisely
Seamless
tracking and tracing of goods is essential for a smooth and efficient
flow within the warehouse, especially so in frozen storage where cold
chains have to be maintained and goods must be tracked at all times –
from receipt through to dispatch. The media used plays an essential role
here, and the most successful solutions can be obtained with the
competence and experience of a reliable provider.
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News and Press Releases |
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Gerresheimer at Pharmapack: With the g guide the optimum solution for biotech and pharma
Düsseldorf, Germany. April 2022. Which packaging or delivery
solution is best suited to the respective active ingredient? In addition
to Gerresheimer's experts, the g guide has recently been answering this
important question for customers and interested parties. At Pharmapack
in Paris on May 18 and 19, Gerresheimer will demonstrate the g guide for
the first time at a trade fair on Stand B60/B64.
More info >> |
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