Keeping PEZ tablets rolling consistently with print upgrade

PEZ is one of the most recognisable sweets brands, known for its collectible dispensers and playful presence on store shelves for generations. But behind the fun exterior is a fast-paced manufacturing operation where precision and reliability are critical.

At the company’s US facility in Orange, Connecticut, more than 1.5 million tablets are produced every hour, with packaging lines reaching speeds of 350 rolls per minute. The plant includes both traversing and linear lines, all operating in a sugar-dusted environment where fine particles hang in the air — conditions that can be tough on coding equipment over time.

Looking to reduce downtime caused by cleaning, maintenance and start-up, as well as to improve print consistency across its lines, PEZ turned to Leibinger for a solution.

“Ever since we switched over to the LEIBINGER printers, the process is simple: turn them on, print, done,” said Gerry Figueroa, PEZ’s Maintenance Lead. “Our downtime has been drastically reduced.”

Unlike traditional CIJ printers that often require daily cleaning, Leibinger systems are designed to stay ready. A fully automatic nozzle sealing system keeps the nozzle airtight during downtime, while continuous ink circulation throughout the system prevents clogs and maintains stable viscosity. Together, these features allow for clean startups — even after extended production pauses. With programmable auto-start, the printers are up and running before the first operator walks in the door.

The Leibinger system also brings added simplicity to daily operations. With VNC (virtual network connectivity), operators can monitor and adjust printers remotely, minimising interruptions on the floor. A single ink formulation is used across all coding processes, streamlining both consumables management and handling. The automatic nozzle seal also ensures that no solvent evaporates during print pauses, significantly reducing consumption.

“It’s more in the background. It’s no longer in the forefront — and that’s exactly what I want from a printer,” said Tony Cangiano, PEZ’s Maintenance Manager.

Precise marking in limited space.

Images courtesy of Paul Leibinger GmbH & Co. KG.