For consumer goods manufacturers, improving packaging operations and enhancing the point-of-purchase appeal of packaged products are top priorities that often go hand in hand. Take the case of Josef Creations, a Providence, RI, manufacturer of souvenirs, novelties, and advertising specialties. Last year, the company installed an AVERY DENNISON™ Elastic Staple™ Variable Needle System (VNS), replacing a manual fastening operation. The system, supplied by the Fastener Division of Avery Dennison Retail Information Services, has proved faster and less expensive than the previous packaging method, while at the same time heightening the visual appeal of Josef Creations' packaged products.
The semiautomatic VNS attaches clear, pliable Elastic Staple fasteners to packaging materials. At Josef Creations, the machine is used to package collectors' spoons, letter openers, bottle openers, key rings, and other products. Previously, these items were attached to display cards using elastic barbs, which workers inserted manually through prepunched holes in the cards -- a time-consuming process.
"With the VNS, the operator simply presses a button and an Elastic Staple fastener is immediately attached," says Rocco Fanella, the company's purchasing manager. "And since Elastic Staple fasteners cost half as much as elastic barbs, the VNS has enabled us to cut fastener-related costs in some applications by 50%."
Changeover to Semiautomatic Fastening
The decision to change over to the VNS was made in October 2001 after Josef Creations officials met with an Avery Dennison Fastener Division sales representative for an onsite product demonstration. Following a several-week trial period, the company installed a VNS system in its boxing department, replacing the hand-fastening operation.
In addition to saving time and reducing fastener-related material costs, the VNS also improves the point-of-purchase appeal of Josef Creations products.
"The clear Elastic Staple fasteners used in these applications are less conspicuous than the elastic barbs used previously," says Fanella. "They have a neater appearance and blend in better with product packaging."
The VNS fastens several hundred thousand Josef Creations spoons and other products annually. The machine is supported on a linear slide mounting stand equipped with precision ball bearings, which controls the system's lateral movement and ensures accurate, repeatable fastener placement. A brush anvil, provided by Avery Dennison Fastener Division, serves as a firm application surface. Products are attached using one or two Elastic Staple fasteners, depending on product size and shape. After fastening, the products are placed in plastic acetate packages or cardboard boxes for shipping.
Trimming fastener inventory is another advantage of the VNS. Previously, Josef Creations had to keep four barb sizes in stock to fit different products and product sizes. Only two sizes of Elastic Staple fastener, the 1/2 in. and 3/4 in. versions, are needed to accommodate the same product line.
