How Toner Farms built a precision marking solution to support consistent CPG packaging production

09.04.2026

Toner Farms Limited faced a critical challenge in maintaining accurate and efficient box labeling during high-volume operations. Located in Grand-Sault, New Brunswick, the farm’s existing marking system could no longer support the complexity of its multi-line production setup. Working through our Channel Partner DMS Marking Coding, Matthews Marking Systems delivered a customized solution featuring the 4” tall T-Series case coding printhead and a custom MPERIA queuing plugin. This integrated system enabled Toner Farms to maintain precise labeling, reduce downtime and improve overall operational efficiency.

Challenge

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The previous system, a competitor’s drop-on-demand product, was outdated, lacked flexibility and often produced poor print quality.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.

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.

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.

“Collaborating with Matthews Marking Systems on the Toner Farms project was a true example of partnership in action. Their innovative approach and technical expertise allowed us to overcome complex challenges and deliver a solution that helped Toner Farms achieve greater efficiency and accuracy for their marking needs.” – Melissa Audette, President of DMS Marking Coding