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Startseite » news » news-0036-Dr.-Karg

Quality is
the best recipe

The baker Dr. Karg's Genuss mit Biss specialises in fine gourmet crispbread and invigorates the standard crispbread with high quality, crafted crispbread specialities, which provide a special moment of enjoyment at every opportunity. Dr. Karg's crispbreads are loved around the world and are currently exported to 25 countries, including Saudi Arabia and Australia. However, the heart of the company still beats in a bakery based in Schwabach. As a result of the constantly growing popularity of the unique gourmet crispbread, it became necessary to expand with another packaging line. After a careful assessment of all the options, a decision was made to cooperate with the coding and marking specialist REA Elektronik with the brand REA JET.

The top down and button up print and apply systems were needed for the packaging lines, which variably mark and label as many packages as possible at maximum speed. The challenges included various label formats that have to be applied by flexible applicator units. Multi-flexible coding and marking systems with maximum performance are needed here.

REA JET:: Packaging line with labeling technology from REA JET.
Packaging line with labeling technology from REA JET.


Customer-specific solution

By integrating the technology from REA, Dr. Karg was able to bring the coding and marking technology up to date and increase efficiency. REA JET print and apply systems were implemented in the line, which apply the colored, preprinted labels to the foil, in which the crispbreads are then packed.

REA JET:: Top down print and apply system.
REA JET top down print and apply system.

REA JET:: Top down print and apply system.
REA JET top down print and apply system.

REA JET:: Top down print and apply system.
REA JET top down print and apply system.

The flow wrap is then heat-sealed and the REA JET bottom up print and apply system marks the label for the back of the packaging, if necessary, inline with variable data such as best-before date, batch number and ingredients.

REA JET:: Bottom up print and apply system.
REA JET bottom up print and apply system.

REA JET:: Bottom up print and apply system.
REA JET bottom up print and apply system.

REA JET:: Bottom up print and apply system.
REA JET bottom up print and apply system.

The goods are then closed with a security clip, checked by a metal detector, weighed and before being packed in shipping boxes are checked again by hand in order to guarantee the 100% quality of the product.

REA JET:: Manual work and a trained eye for high product quality.
Manual work and a trained eye for high product quality.

Many tens of thousands of packages are labeled and marked every day. In order to guarantee the high speed in the packaging line, all labels to be printed will be marked using the integrated thermal transfer inline print module from REA JET and then stored in a loop buffer. This buffer allows labels to be applied to the packaging constantly, at the highest quality and at maximum speed if required.

REA JET:: A selection from the crispy Dr. Karg product range.
A selection from the crispy Dr. Karg product range.


Perfection is mandatory

In order to correspond to the high quality of the products, a consistent appearance of the packaging is required through the precise positioning of the label. This accuracy is ensured by, among other things, an electrically supported label handling, as permanently consistent tensile forces dominate here. REA JET supplies the thermal transfer foils specially designed for the label material in order to guarantee the best possible print result.

REA JET:: High quality requirements at all production stages for optimum product quality.
High quality requirements at all production stages for optimum product quality.

REA JET:: High quality requirements at all production stages for optimum product quality.
High quality requirements at all production stages for optimum product quality.


Positive resonance

At Dr. Karg they are very impressed by the customers-specific solution and value the reliability of the high performance system: "REA JET offers the best possible combination of quality and speed. Products from REA are already in use in several packaging lines. As a result of the new technology we have been able to increase the production tempo and process security. The system runs seamlessly and reliably," explains packaging manager Detlev Schubert.

The competence and customer service of REA JET was also praised. The manufacturer of industrial coding and marking systems, which was founded more than thirty years ago, develops and produces all its products in Germany and has a global sales and service network. The company offers need-based solutions with modern interfaces for network integration, communication with production controlling computers and printing from databases. The variable systems from REA JET are ideal for the requirements of the food industry, which has to mark its goods reliably and reproducibly. Compact dimensions and the modular structure of the systems guarantee flexible integration into existing lines.


Modern alternative

In addition to the labeling solutions, several thermal transfer inline print modules from REA JET are used by Dr. Karg for direct foil marking.

REA JET:: Direct marking of packaging foil with thermal transfer inline print modules from REA JET.
Direct marking of packaging foil with thermal transfer inline print modules from REA JET.

REA JET:: Direct marking of packaging foil with thermal transfer inline print modules from REA JET.
Direct marking of packaging foil with thermal transfer inline print modules from REA JET.

In the area of contactless product marking, REA JET offers modern alternatives to many Continuous Ink Jet systems. These almost always used inks and thinners containing solvents and are therefore only suitable for use in the food industry with restrictions. Coding and marking systems from REA JET based on HP print technology are maintenance-free and future-proof, and allow environmentally friendly, solvent-free printing. The high resolution printing facilitates a comprehensive product declaration corresponding to the requirements of the new EU Food Information Directive. Thanks to maintenance-free HP print head technology there are no additional costs for service or spare parts. The system is controlled either by PC of directly via the display. The user menu is a graphic user interface with a list that guides the user and is intuitive to use. The use of True Type fonts and unicode allows texts to be printed in any desired language.

As a result of the strongly growing use of barcodes and DataMatrix Codes in product marking, REA JET, in combination with code verification systems from REA VERIFIER, offers critical customer advantages.

REA JET:: Director Dr. Klaus Kargs´s name stands for the high quality of the products.
Director Dr. Klaus Karg´s name stands for the high quality of the products.

REA JET:: They are rightly proud of the high quality of Dr. Karg products.
They are rightly proud of the high quality of Dr. Karg products.

In the current projects, Dr. Karg and REA JET have become partners who combine tradition with the modern, experience with innovation and quality with security.


Info boxes:

About Dr. Karg
The company, which is based in Schwabach in Franconia, was founded in 1950 and has become established as a manufacturer of high quality baked goods. Dr. Karg is still a family-owned company and supplies almost all large German supermarkets with crafted crispbread specialities under the brand Dr. Karg. The company also belongs to a dense branch network of bakeries, which supplies the region with flavoursome bread and crispy rolls every day. Despite the many years of growth, only conventional and organic quality products are manufactured regionally, which comply with the strictest quality standards (for example, International Food Standard IFS and BRC).


About REA JET
REA JET is a specialist for coding and marking as well as labeling systems. The products are sold globally and are tried and tested in a variety of industries. REA JET and the manufacturer of code verification devices REA VERIFIER are divisions of REA Elektronik GmbH, which was founded in 1982. Today the company employs more than 300 people at its headquarters in Muehltal close to Frankfurt am Main. All REA products are developed and produced there and are 100% Made in Germany.


REA JET Contact:
REA Elektronik GmbH
Reto Heil
T: +49 (0)6154 / 638 0



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