Toner Farms - Precision Marking for CPG Packaging

Channel Partner: DMS Marking Coding
End Customer: Toner Farms Limited
Industry: Consumer-Packaged Goods, Potatoes
Location: Grand-Sault, New Brunswick, Canada
Products: Custom MPERIA Plugin and T-Series Printhead

Toner Farms, a leading high-volume potato producer, needed a smarter and more dependable way to mark packaging during the sorting and boxing process. With distribution spanning multiple countries, accurate and detailed markings on each package were essential for traceability and compliance. However, their previous marking system lacked the flexibility to keep up with the fast-paced, dynamic nature of their production line, resulting in inefficiencies and potential labeling errors.

Their facility features a central hopper that feeds potatoes into multiple lines, each filling boxes to a target weight of 50 pounds. Once filled, each box is released onto a main conveyor for labeling. The challenge was to ensure that each box received the correct alphanumeric identifier based on its originating line. Boxes were not always released in sequence. For example, if a box from Line 1 was released and then a box from Line 6 was delayed due to a jam, the system needed to ensure that the next box, perhaps from Line 2, still received the correct mark.

The previous system, a competitor’s drop-on-demand product, was outdated, lacked flexibility and often produced poor print quality. This led to mislabeling, production delays and rework. Toner Farms needed a solution that could intelligently track and label boxes in real time, regardless of the order in which they were released.

The Solution

Matthews Marking Systems, in collaboration with DMS Marking Coding, delivered a custom-engineered solution tailored to Toner Farms’ operational needs:

• T-Series Printhead: Applied unique alphanumeric codes to each box as it passed along the main conveyor.
• MPERIA Controller: Served as the centralized control hub for the marking system.
• MPERIA Custom Queuing Plugin: Developed by Matthews’ Engineering Solutions team, this software plugin ensured that each box was marked accurately, even when boxes were released out of order. The plugin used a combination of sensors and timers to track box movement and dynamically manage the print queue.
• Spring-Loaded Bracket and Purpose-Built Stand: Designed to maintain optimal throw distance and protect the printhead from contact with moving boxes. The bracket’s rollers helped ensure consistent print quality by keeping the box at the ideal distance from the printhead.

This solution eliminated the need for third-party middleware or additional hardware, which is often required by competing systems. The MPERIA platform allowed for seamless integration and customization, giving Toner Farms a streamlined and efficient marking process.

To overcome the installation challenges, Matthews Marking Systems implemented a precise sensor configuration to ensure accurate detection and printing. Eight sensors were strategically positioned to identify each box as it exited the line, send the signal, and trigger the correct print. The design also accounted for potential manual interventions, such as removing a box, by preventing these actions from causing unintended prints.

The Results

The new system provided:

• Improved Accuracy: The queuing plugin significantly reduced the risk of mislabeling, even in complex release scenarios.
• Operational Efficiency: The system minimizes downtime caused by box jams or misfeeds, reducing the need for manual intervention. It also provided better traceability for Toner Farms.
• Consistent Print Quality: The spring-loaded bracket ensured optimal throw distance, resulting in high-quality, legible marks on every box.
• Simplified Integration: The MPERIA controller allowed direct interfacing without the need for additional software or hardware layers.

Why Matthews

Toner Farms selected Matthews Marking Systems for its ability to deliver a flexible, tailored solution that addressed a specific production challenge. The combination of robust hardware and custom software development set Matthews apart from competitors and provided Toner Farms with a future-ready marking system that supports their operational goals.

About DMS Marking Coding

Founded in 1977 as Diagent Marking Systems, DMS Marking Coding has built a strong reputation in the field of traceability and industrial identification. Now led by third-generation owner Melissa Audette, the company offers a wide range of solutions including inkjet systems, coding and labeling equipment, thermal printers, barcode readers, traceability software, and consumables like thermal labels and ribbons. With a mission to optimize operational efficiency and automate production processes, DMS serves manufacturing companies across industries with a commitment to professionalism, collaboration, and customer service. Their team of dedicated experts and technicians work closely with clients to deliver tailored solutions that make a lasting impression.

About Toner Farms Limited

Toner Farms Limited, operating as Toner Produce Ltd., is a leading potato producer located in Grand-Sault, New Brunswick. The farm benefits from some of the most fertile land in western New Brunswick and is recognized for its advanced crop rotation program, growing potatoes only two out of every five years to ensure consistent, high-quality yields. Committed to sustainable agriculture, Toner Farms implements extensive land management practices including contouring, terracing, and waterway systems to prevent erosion and preserve soil health. The farm is a proud participant in the New Brunswick Environmental Farm Plan and is certified under the CanadaGAP On-Farm Food Safety program. With modern planting, harvesting, and storage systems capable of holding up to six million pounds of potatoes, Toner Farms continues to set the standard for responsible and efficient potato production.