Automated Solutions for Improved Shelf Appeal in the Cheese Aisle

Competition in the dairy aisle is higher than ever, creating new pressures for cheese producers. A proliferation of SKUs, combined with the rapid growth of private-label brands, has made secondary packaging performance critical at every stage of the supply chain.

Manual packing is still common in cheese facilities, but it is costly and inefficient, especially for growing businesses and co-packers that may need to accommodate a variety of formats. Automation can help producers and co-packers achieve their production goals and meet retailer demands.

But which type of automation is best suited for specific secondary packaging applications in the cheese industry? We will explore different packaging formats and why shelf-ready packaging has become so prevalent in the cheese aisle.

Other topics we will focus on in this article include:

• The limitations of manual packing and the challenging environment for cheese production.
• Operational challenges retailers face that impact their secondary packaging preferences.
• How BPA’s Easy-D® retail-ready case offers many advantages for manufacturers and retailers.
• Which BPA machines are best suited for shelf-ready and other packaging formats.

Why manual packing isn’t suitable for new retailer demands

While manual packing is still available, it doesn’t provide the speed or flexibility required for complex runs that feature new packaging formats and diverse cheese products. For example, shelf-ready packaging (SRP) is increasingly becoming a retail requirement that is difficult to repeat consistently manually and one that manufacturers will need to consider.

This shift is driven by several key operational challenges:

• Retail Labor Shortages: Packaging must minimize stocking time and reduce in-store labor demands
• SKU Proliferation: Expanding variety across flavors, formats, and seasonal products increases complexity
• Sustainability Mandates: Ongoing pressure to reduce plastics and adopt recyclable materials
• Inventory Velocity: Strong shelf presentation is essential to drive faster product turnover

Environmental conditions in the dairy industry are difficult for humans to work in for extended periods of time. Our machinery is built to handle these tough environments with stainless steel full washdown and more. We also have a vision guided robotics system for handling naked cheese that was designed and built to be 3A compliant.

Using BPA’s Easy-D® for retail-ready results

Standard perforated tear-away cases often leave jagged edges that undermine brand appearance. BPA’s Easy-D® case solves this by combining the structural integrity of a shipping case with the polished look of a dedicated retail display. Engineered as a wraparound design, the Easy-D® features a machine-cut front panel that wraps cleanly around the corners. Other features include:

• Approved for the Shelf: A Walmart-approved SRP design that ensures products move from the pallet to the cold case with zero friction.
• Operational Versatility: Easy lay-down loading and shipping, converting quickly into a shelf-ready tray with vertically standing contents.
• Cost-Effective: No royalty payments, making it an ideal long-term investment for high-volume producers and co-packers.
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What machines are best for shelf-ready and other formats

To realize the full potential of Easy-D® cases, selecting the right downstream automation is critical. BPA offers a range of solutions tailored to product format, line speed, and available footprint. These machines can be integrated with the Easy-D® to handle multiple case styles or product configurations on the same line.

1. Wraparound Case Packers (100, 200, & 300): Forms the case around the product, then loads and seals it in a single integrated footprint. Ideal for standard-shaped products and high-speed lines, providing a tight, secure fit.
2. Vision-Guided Robotics: Uses a combination of four- and six-axis delta robots and an integrated vision system to identify and pick up irregular or delicate products, such as naked slices or slumped pouches. Our robotics solutions precisely place them into the Easy-D® case for complex pack patterns and a perfect billboard effect presentation.
3. Gantry Systems: Picks up bags from a vertical bagger and arranges them in a neat, slightly overlapping pattern before loading them horizontally into the Easy-D® case. This ensures the bags remain upright, stable, and visually appealing when the retailer opens the box.
   
   

Alternative solutions for foodservice & bulk

Not every application requires the premium aesthetics of the Easy-D. For co-packers and foodservice suppliers, the priority is moving high volumes of product efficiently:

• Gravity case packers are ideal for bulk bags in 4–5 bag foodservice cases. Products can be dropped into cases without precise pack pattern concerns.
• Gantry case packers can also be used to load cheese bags and tubs into standard RSC cases when visual presentation is less critical.
  
  

Across all systems, the common thread is flexibility. BPA machinery is engineered to support a wide range of formats and products, ensuring producers can meet both current demands and future packaging needs.

See the Easy D® and Wraparound live at CheeseExpo

BPA will be an exhibitor at CheeseExpo in Milwaukee, WI, from April 14-16. In addition to speaking with attendees 1-1 about their secondary packaging needs, we will also be showcasing our Easy-D® concept live in our booth.

We will be featuring our Wraparound 200 case packer loading pouches of cheese into our Easy-D® retail-ready display case. Discover firsthand how this integration supports erecting, loading, and closing shelf-ready cases with ease. Come see us at Booth 249.

If you have any questions or are interested in automation and can’t make it to the trade show, contact us today to speak with our experts.