Meat Processor Achieves Zero Downtime & Better Traceability

Solar Meats LLC Achieves Zero Downtime & Better Traceability with TSC Printers and the TEKLYNX Software Development Kit

TOPICS: PRINT AUTOMATION, FOOD & BEVERAGE, MANUFACTURING

Solar Meats LLC, a growing, quality-focused meat processing company based in Wisconsin, specializes in custom butchering and retail cuts for local producers. As a dedicated partner in the local food economy, Solar Meats is experiencing rapid growth, which accelerates the need for modernization. Their continued expansion requires a labeling and data management system capable of handling high-volume production while ensuring stringent food safety compliance and market-ready label quality.

The Solar Meats legacy system caused significant bottlenecks in their production flow, impeding their ability to scale efficiently. With the previous system, any equipment failure required taking the unit out of production and waiting for the equipment vendor to make a costly on-site visit. To keep production going, Solar Meats purchased “backup” systems to use while waiting for technicians, increasing their total cost of operation.

The old system proved difficult for their office manager to update efficiently. Changes needed to be applied sequentially to multiple devices. Beyond delays, this created an increase in labor costs. In addition, the outdated infrastructure risked inaccurate labeling, potentially leading to non-compliance with federal traceability requirements for packaged meat in food processing. The outdated infrastructure limited label size, resulting in inconsistent print quality and impacting product presentation.

Solution

TSC Auto ID model MB241 industrial barcode printers power a comprehensive, real-time labeling and traceability platform implemented by Pioneer Retail Systems, LLC, utilizing ScaleFusion software from StrategyBytes, LLC, and the TEKLYNX Software Development Kit (SDK). Together, the solution enables seamless integration and immediate data synchronization.

Pioneer Retail Systems chose TSC printers for superior print quality, efficiency, and proven reliability in rugged, high-volume food processing environments.

StrategyBytes integrates the TEKLYNX SDK to simplify labeling tasks, while ScaleFusion software ensures accurate weights, tracks all production, and prints attractive, easy-to-read labels. ScaleFusion's network connectivity instantly transfers label format and ingredient changes from the administrator to local workstations. By generating high-quality, clear barcode labels (which serve as the physical data carriers for lot, weight, and ingredient information), the TSC Auto ID printers ensure accurate data capture necessary for digital traceability.

This seamless tracking capability sets the foundation for advanced automation capabilities to further optimize inventory management. The decision to standardize on TSC printers, selecting the MB241, is driven by the need for proven reliability, minimal support overhead, and seamless compatibility with critical TEKLYNX labeling software components.

Results

As Solar Meats notes, the printers are known for their “lack of having to call support. They just work,” providing consistent operation essential for perishable goods processing. “In the 18 months that we’ve been using the Pioneer system, we have not had one issue with the printer, not one hiccup,” says Rich Sitarski, Partner of Solar Meats. This reliability is matched by the print quality of TSC, which meet strict industry and retail packaging standards, while producing easily scanned barcodes and clear, crisp text.

To achieve this level of performance, Pioneer Retail Systems, StrategyBytes, TSC Auto ID, and TEKLYNX provided a reliable, industry-proven solution that enabled Solar Meats to focus entirely on data and compliance management through ScaleFusion, giving them the confidence that the printers will print accurate labels every time. Rich describes, “With the old system, it was strictly manually counting, manually adding weights. This would add 10% time to each order.”

The new system allowed changes, such as ingredient corrections or format adjustments, to be implemented by Solar Meats’ staff in seconds—eliminating the previous fifteen-minute-per-printer production disruption and drastically improving operational efficiency.

Pioneer Retail Systems helped Solar Meats fix problems with a phone call and can even take control of their systems as needed. This dramatically increased uptime and eliminated expensive onsite repair visits, or lengthy service delays. Rich says, “I can reach out and within five to ten minutes Pioneer is calling me back and they’re fixing it.”

“With the new TSC system, changes happen in seconds. It goes to all the computers instantly, with no disruption. If an ingredient is wrong or a label needs fixing, I can do it myself. It’s fast, easy, and doesn’t slow anyone down.” says Susie Steiskal, Office Manager, Solar Meats.

LEARN MORE ABOUT THE TEKLYNX SDK

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This content was originally created and published by TSC.