Delibarn creates stable inner packs with cross-banding

Delibarn, a leading Belgian meat processing company, has built a reputation for excellence in slicing and packaging high-quality charcuterie products. These include a wide range of cold cuts, such as ham, salami, and sausages, which are distributed to large retailers like Delhaize and Carrefour.

Once the individual packs are sealed and labelled, they still need to be grouped into fixed quantities before being placed into reusable crates for distribution. In theory, this sounds simple. In practice, the flexible trays, chilled production environment and presence of moisture made it difficult to keep the stacks stable during handling and transport.

More than ten years ago, Delibarn discovered banding at a trade show in Mechelen. What began as a small-scale trial with a Stand-Alone machine gradually developed into a standard part of the company’s packaging process. Today, more than 85% of Delibarn’s production lines end with automated banding machines.

From individual meat packs to crate-ready bundles

Delibarn packages each product according to the requirements of the retailer. The sliced meat is placed on flexible trays, sealed with film and labelled before being grouped into predefined quantities.

These grouped packs, also known as inner packs, help Delibarn organise orders, simplify handling and make efficient use of the available space inside reusable crates. The number of packs in each bundle can vary depending on the product, retailer or order, so the solution needs to be both secure and flexible.

When one band was not enough

Delibarn initially tested banding by applying a single band around each stack. The machines proved reliable, easy to operate and efficient in their use of material.

However, some bundles still lacked the stability required for daily distribution. Because the packs were flexible and sometimes slippery from moisture or condensation, one tray could move out of position. As soon as that happened, the band could lose tension, and the rest of the stack could come apart.

The team therefore needed a way to secure the bundle in more than one direction.

 

The move to cross banding

Together with Bandall, Delibarn tested a cross-banding setup.

First, a band is applied around the stack in one direction. The bundle is then rotated 90 degrees before a second band is added across it. The two bands form a cross around the packs, holding the stack securely across both its length and width.

That additional support made a clear difference. The bundles remained stable during handling, crate loading and transport, even in chilled and humid production conditions.

Built into the packaging process

Delibarn first used Stand-Alone machines to test the concept under real production conditions. Once the results proved successful, the company gradually introduced automated banding systems at the end of more packaging lines.

The process now fits naturally into the existing workflow. After the individual meat packs are sealed and labelled, they are grouped into the required quantity, cross-banded and prepared for crate loading.

This allows Delibarn to create consistent inner packs without adding unnecessary manual handling or slowing down production.

Stable bundles and better use of crate space

Cross banding gives Delibarn a practical way to keep flexible meat packs together while using only a small amount of packaging material.

Because the bands take up very little space, the bundles fit neatly into reusable crates and the available volume can be used efficiently. The fixed quantities also make orders easier to organise and distribute.

Once the crates reach the retailer, the bands can be removed quickly so the individual packs can be placed directly onto the shelf.

As a result, Delibarn benefits from:

• Stable bundles of flexible meat packs
• Reliable performance in chilled and moist conditions
• Consistent quantities per inner pack
• Efficient use of reusable distribution crates
• Less packaging material than full wrapping
• Reduced manual handling
• Easier shelf replenishment

From trade show discovery to everyday solution

What started as an unexpected discovery at a trade show has grown into a long-term packaging strategy.

Banding is now a core part of Delibarn’s operation, with automated systems installed across most of its production lines. For Delibarn, the benefit is straightforward: the packs stay together, the crates are filled efficiently, and the process performs reliably every day.