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Fluxcode’s Track and Trace solutions. Photo credit: Fluxcode GmbH
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René Petton (left) and Mitja Carstensen (right), Fluxcode’s co-founders, co-developers, and co-general managers. Photo credit: Fluxcode GmbH
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Propix Technologies’ premises in Pune, Maharashtra, India. Photo credit: Propix Technologies Pvt. Ltd.
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Ashwin Kapadnis, director, Propix. Photo credit: Propix Technologies Pvt. Ltd.
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Nitin Patwardhan, director, Propix. Photo credit: Propix Technologies Pvt. Ltd.
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T&T now being mandatory almost everywhere, it’s a good idea to bring existing systems up to date.
Track and Trace (T&T) protocols for tobacco and tobacco products have become a mandatory procedure in many territories, most notably the EU and the US. But, they are not globally uniform. Russia, for example, deploys a rather complicated T&T protocol that is quintessentially incompatible with that of the EU. On the other hand, many less-developed markets haven’t implemented a T&T protocol at all yet, which may prevent their companies from exporting raw tobacco or finished products to certain places. Any T&T system relies on two distinct components: hardware integrated with processing or production machinery and the software that runs and controls that hardware (as well as its data) and is tweaked to be compliant with the relevant protocol.
Rolling out the “Red Carpet”
While plenty of T&T developers focus their efforts on industry sectors, such as pharmaceuticals, food and beverage, automotive, chemicals and many others, precious few are dedicating themselves to the tobacco industry. Among this illustrious lot are Switzerland’s Inexto and – as the latest newcomer – Germany’s Fluxcode GmbH. The German outfit’s co-founders and, incidentally, co-general managers, René Petton and Mitja Carstensen, both boast a professional background in the tobacco sector, having previously worked for a German tobacco manufacturer for many years before taking their first steps into the T&T arena in 2017. Together, they developed a T&T software called “Red Carpet”. After Russia implemented its T&T protocol at the end of 2019, the pair went to task and re-worked “Red Carpet” with a double coding system. “We can proudly claim that [Red Carpet] was the first software in the world to allow non-Russian manufacturers to produce tobacco products for the Russian market under complete adherence to all T&T requirements over there,” René Petton told Tobacco Asia.
The birth of FluxcodeSuite
Encouraged by the success of Red Carpet, Petton and Carstensen decided to leave their employer in 2020, founding Fluxcode GmbH. Over the next couple of years, the pair completely repro-grammed and optimized the software, rechristening it “FluxcodeSuite” and introducing it to a global public at the 2022 InterSupply/InterTabac show in Dortmund.
“I recently analyzed our code and found that we have programmed almost one million lines of code in the last two years,” said Mitja Carstensen. “I was really surprised about that, thinking to myself: ‘That’s not such a bad feat for a newbie’.” It surely was worth it, though. The software is now so comprehensive that it is able to handle practically all T&T systems in the world – with one exception. “South America’s SICPA system unfortunately is set up in a way that it does not allow competition from [software] suppliers from out-side the region,” noted Petton.
Easy and intuitive to use
The other strong point of FluxcodeSuite is that despite its complexity it is extremely easy and intuitive to use. A remotely-conducted training course, which the company provides as part of its service package, hones key operating personnel to get up to task with the software’s functionalities. Installation likewise is a breeze, according to Carstensen.
“Provided that all relevant data such as IP addresses and access data of the various hardware components such as printers and aggregators are available, installation and setup can be accomplished within one to two hours,” he claimed.
But, Carstensen also cautioned that in cases of production lines that lack T&T hardware, sourcing, acquiring, and installing those components, as well as registering a unique identifier (UID) at all relevant official issuers “can easily take up half a year or more.”
However, where relevant hardware T&T components already exist (and that presumably should hold true for reasonably up-to-date plants), the FluxcodeSuite usually would function with most, if not all of them. For customers who would like to either upgrade or replace their hardware with minimal production out-times, Fluxcode works closely with reliable partner companies, such as German hardware provider Hermos AG. Alternatively, aggregation systems, code printers, cameras, ejectors, and what not can be easily obtained from a myriad of other suppliers. (For more on that, please read the below section on Indian company, Propix.)
Modular design for all requirements
Where the FluxcodeSuite also shines is its modular design, which allows the customer to choose what they really need.
“For instance, that means that a customer who is only interested in ordering [product] codes only needs to license [our] FluxOrder module but is not obliged to purchase the entire suite,” emphasized Petton. “We are very flexible there and make almost everything possible.” A single server (which by default must be a Microsoft server) controls all active modules and handles data exchange and private repository, while Microsoft’s Internet Information Service (IIS) hosts the FluxWeb web application remotely. To safeguard against misappropriation or software piracy, the most important FluxcodeSuite codes are encrypted and require the user to deploy a license key to unlock them. It seems to work splendidly, as according to Carstensen the company has so far recorded not a single piracy attempt. Of course, that also gives users peace of mind that their production data are safe. Which brings us to the actual hardware needed for efficient and – more importantly – protocol-compliant hardware.
Propix: Track and Trace Hardware from India
India has matured into an important global supplier of production and processing machinery to a wide range of industry sectors, including tobacco. The country’s universities and colleges shell out huge numbers of mechanical design and engineering graduates every year. In the tobacco arena, the country caters to practically every step in the supply chain. From agricultural mechanization, over primary and secondary processing, to aggregation, packing, labeling, and wrapping – Indian manufacturers almost certainly have the right hardware solution at the ready. And as complex T&T requirements have become mandatory almost everywhere, a number of Indian companies have taken to offering ingenious T&T systems as well. Among this very specialized league of suppliers is Propix Technologies Pvt. Ltd.
Fully FCTC-compliant Track and Trace
Founded in 2008 in Pune in the central-western state of Maharashtra, Propix from its very start targeted a broad array of different industries, supplying them with vision inspection, industrial automation, robotics, and T&T systems. In 2010, when T&T compliance became mandatory for all pharmaceutical exports from India, Propix rolled out its dedicated “Packi Track n Trace” suite. The ISO9001-certified firm eventually also adapted the suite for use in the tobacco manufacturing industry, naming that offshoot a not very enigmatic “Tobacco Track n Trace”. “The suite’s backbone is its software, which is fully compliant with the WHO Framework Convention on Tobacco Control [FCTC] protocol,” explained Propix’ director, Nitin Patwardhan. Additionally, the software can also handle the European Union’s TPD2 T&T provisions, as well as more complicated national frameworks such as those of Russia or the UAE.
No such thing as “off the shelf” solutions
The Packi suite comprises a host of hardware modules needed for implementing all relevant T&T requirements: serialization printers, optical sensors and cameras, pneumatic ejectors, bundling aggregators. While several of these components, such as the AGNI cigarette bundle aggregator, have been in-house developed by Propix, others – e.g. cameras, sensors, and certain semiconductors – are supplied by partner companies.
“Everything is then assembled here in Pune, where all ordered system suites also undergo rigorous quality control and functionality testing,” Nitin said. Propix follows a 5-step customization regimen (see table), considering the client’s particular manufacturing environment. “Each and every set-up has to be process-oriented and production line specific” he assured.
As any T&T system usually has to be integrated with an already existing production line, it makes providing an “off the shelf” solution problematic. Yet, most tobacco companies already put at least some T&T infrastructure in place even before tougher regulations came into effect. So, how easy is if for such companies to upgrade in order to become fully compliant?
“Major components for printing, inspection, and ejection generally are already present in any cigarette packer machine,” confirmed Ashwin Kapadnis another one of Propix’ directors. “If these components are capable of inspecting and coding in line with current compliance rules, then they can continue to be used, reducing investment and saving operators a good amount of money.” In such cases Propix would furnish the customer with a proposal, detailing which of the existing hardware is good to go and which components need to be replaced for newer ones. According to Ashwin, it was standard practice for a Propix technical team to visit the customer’s facility and study the onsite production line and its various T&T set-up.
Tardies still are around
Every now and then Propix encounters cases where a tobacco company never got around to implementing a T&T system to begin with. Ashwin explained there were four main reasons why certain firms may have neglected their T&T procedures:
1 – T&T compliance was not mandatory in the market region where they are active;
2 – The company thought available T&T solutions too expensive;
3 – The company had very little business in markets where T&T is mandatory;
4 – T&T systems are regarded merely “a tool for brand protection and internal data collection”, making the company wary of major investment.
These reasons notwithstanding, Ashwin’s colleague Nitin Patwardhan cautioned that an inadequate – or even non-existing – T&T system can have serious ramifications for a company’s efforts in brand building and market share development. “If a firm’s T&T procedures are not compatible with the FCTC protocol or any other relevant directives, it won’t be able to legally distribute and sell its products in most markets. It’s a simple as that,” he pointed out. “And even if that company should reconsider and implement a system, it might be difficult to re-enter the market and recapture [previous] market shares.” Nitin’s message is clear: it’s highly advisable not to miss the T&T train.