The production of Synergy labels sets is conducted under supervision of experts from the field of material engineering, production, industry and management specialists. Production is carried out in six main stages, from characterization to supply of the products on the customer’s site.
The work process is consistently monitored in multiple stages – throughout production – under Synergy’s Chief Engineer. During the process, stringent quality assurance is maintained, and when necessary, rolls are destroyed and production starts afresh. At the final stage of production quality control (QC) is applied according to the standards outlined in the Synergy Standard Certificate.
Synergy continually invests resources in developing new standards of quality assurance and uses advanced monitoring equipment. Stringent supervision ensures the efficiency of the production chain and results in high quality products, conforming to the ISBT 128 standard and the Israeli Blood Bank’s quality assurance guidelines.
Stages of production:
1) Clarifying the needs and characterizing the product:
Studying the unique needs and demands of the client is done by Synergy’s Chief Engineer in an interview, during which the required specifications are learned and the future product characteristics are outlined.
2) Manufacturing raw materials in the material production facility:
In the material production facility the rolls from which Synergy B72 labels are produced, by lamination and adhesion of three layers of raw materials: a silicone back, glue, and the label’s front, made from polypropylene.
The raw materials making up the Synergy B72 product line are made from environment-friendly, perishable materials which were developed for maximum compatibility with the needs of global blood banking by experts in material engineering. The most advanced printing machinery available is used in production and quality assurance is done on multiple samples. Samples are tested and stored in the department’s laboratory, according to batch numbers, for a seven year period.
When the rolls are completed, they are cut out to slices according to the different product specifications of the Synergy B72 series. From there the slices are transferred to the converting department.
In the converting department sets of labels are produced from the slices according to the Synergy B72 specifications. During label production multiple samples are tested for quality once again, to ensure the uniformity and quality of cut of the labels’ edges.
Each roll passes to the next stage only when it is supplied as a whole, without having undergone patching. A roll that was torn during production for any reason is completely destroyed.
During this stage, sets of Synergy 7 labels, supplied blank and unprinted, undergo a process of cleaning with air-pressure to remove production line leftovers, monitored for quality once more, and then packaged.
Sets intended for the Synergy 9 label set, supplied with a pre-printed barcode, are also air-pressure cleaned and then transferred to the printing department.
In the printing department sets received from the converting department are printed with a barcode, according to the customer’s demand and in accordance with the ISBT 128 standard.
The department’s employees verify that the set rolls are clean and intact prior to printing.
Printing is done using machinery and printing materials which are the most advanced in the field, to ensure that the print would withstand cold (including conditions of deep-freezing), heat, centrifuges, contact with fluids (including blood particles) and with hands.
Throughout printing a verifier ensures the readability and quality of print, in full compliance with highest standards (known as “A” quality). At the end of printing each label roll, a computerized verifier report is attached to each roll.
In case a set is not up to the readability and quality standard or if it is damaged, not whole, or torn for any reason during printing, the set is destroyed as a whole.
5) Quality Control
At the end of production additional quality assurance is carried out in the printing department, and then the material is transferred to the quality control department, housed in a different facility. In the QC department a careful scrutiny is done by Synergy’s Chief Engineer according to both the client’s demands and the ISBT 128 standard.
Quality control on pre-printed Synergy 9 labels is done using a designated program (the Syn-tech Software) developed in-house. Testing is done by conducting laser-readings on each set of labels – to verify the label’s print is identical to the software registry. An additional, parallel test ensures the durability of print and verifies that all data specified in the customer’s demand is on the labels.
6) Packaging, delivery and on-site verification:
The product is packaged in nylon and the package includes a detailed representation of the barcode numbers in each roll and final quality control stamps of approval. Each delivered package contains a Synergy Certificate that states the batch number, range of label numbers within the package and other details. The certificate is a guarantee for the quality of the package contents and it is signed by the company’s engineer, with a statement that the contents withstood successfully all stages of quality assurance.
Supply, logistics and delivery of the products is accompanied by a Synergy-appointed staff member, who verifies the delivery details on the client’s site.