Customer Overview
A skincare manufacturer producing body lotions, oils, and other personal care products needed to improve efficiency and eliminate manual labeling and handwritten date/lot codes. Their products are sold in several container styles including spray bottles, jars, and paper tubes. Each product requires a label as well as a clearly printed manufacturing date and lot number.
Due to customer confidentiality agreements, the company operates under a non-disclosure agreement and is referenced anonymously in this case study.
The customer's product variability made it difficult to standardize labeling and coding using manual methods.
The Challenge
Prior to contacting Pro Pack Solutions, the manufacturer relied on a manual process for both labeling and product coding.
Operators would first apply labels by hand to each container. After labeling, employees would manually write the manufacturing date and lot number directly onto the label.
This approach created several operational issues.
- Labor Intensive Process - Hand applying labels and manually writing codes took a significant amount of time per unit
- Inconsistent Label Placement - Manual labeling led to inconsistent label height and presentation.
- Legibility Risk - Handwritten codes created readability issues and required rework
The manufacturer began looking for a solution that could automate both processes while maintaining flexibility for multiple container types.
Equipment Solution
After discussing their requirements with Pro Pack Solutions, two equipment options were presented. The manufacturer ultimately selected a system built around the following components:
- TAL-3100R Label Applicator
- Smart-Jet BLUE Inkjet Printer
This configuration allows labels to be applied to the container while the inkjet printer simultaneously prints variable data directly onto the label during the labeling process.
The system prints two lines of text:
MFG ON [MM/YY]
LOT [JJJJ]
The labels used in production were redesigned with a dedicated white box print area. This ensured consistent contrast for black ink coding across their product lines.
By combining labeling and coding into a single automated process, the system eliminates the need for manual writing while improving consistency.
Packaging Variability
One of the biggest concerns for the customer was their wide range of packaging formats. Their production includes multiple bottle and label combinations.
Examples tested during evaluation included:
- 4 oz spray bottle
Label size: 2" x 5" - 2 oz cosmetic jar
Short jar with removable metal lid
Label size: 3/4" x 4" - 3 oz paper tube container
Label size: 2.5" x 5"
The variety of container shapes made testing especially important before committing to a system.
Sample Testing Process
Pro Pack Solutions encourages customers to test equipment with their labels and containers. This allows potential issues to be identified early and shows exactly how their containers will perform on the equipment.
- Customer Provided Samples - 3-4 containers & approximately 150 ft. of labels of each container style were sent to our warehouse
- Sample Review - We contacted the customer to review the samples and ensure testing conditions would accurately represent the customer's production environment
- In-House Equipment Testing - Samples were run through the TAL-3100R Total Solution applying labels and printing date/lot codes simultaneously
The testing allowed the team to evaluate:
- Label placement consistency
- Print clarity and alignment
- Container handling
- Overall system workflow
Video Demonstration
The entire test process was recorded to provide the customer with a clear view of how the equipment performed with their packaging.
An unlisted YouTube video was created and shared directly with the customer. This allowed them to watch the testing process in detail and review the results with their internal team.
Live Changeover Demonstration
After reviewing the video, the customer wanted to better understand how quickly the system could switch between different containers and label sizes. To demonstrate this, we scheduled a live FaceTime session.
During the live call, we showed changing between label sizes, adjusting for different container shapes, and setting up the printer for the correct print location
Seeing the changeover process in real time gave the customer confidence that the equipment could handle their product variety without excessive downtime.
Implementation Results
After completing the testing process and live demonstration, the manufacturer approved the system and moved forward with purchasing the equipment.
The impact on their production workflow was immediate.
Two Processes Became One
Previously, operators had to complete two separate tasks:
- Apply labels
- Hand write lot numbers and manufacturing dates
With the TAL-3100R and Smart-Jet BLUE printer, labeling and coding now occur in a single step.
The label applicator applies labels at a consistent height. This gives the customer the desired packaging presentation and creates uniformity on the retail shelf.
The inkjet printer applies crisp, readable text directly onto the label as it is applied to the container. This eliminates handwriting errors and improves traceability.
For this manufacturer, the labor savings alone are expected to offset the equipment investment within a few months.
Why Testing Matters
This project highlights the importance of testing packaging equipment using real containers and labels. Every packaging environment is different. Container shapes, label materials, and print requirements can all affect how equipment performs.
By sending samples and reviewing real test footage, the customer was able to evaluate the system with confidence before making their purchase.
Equipment Used
- Label Applicator: TAL-3100R
- Coding System: Smart-Jet BLUE Inkjet Printer
- Ink Color: Black
Example print format:
MFG ON [MM/YY]
LOT [JJJJ]
Need Help Automating Labeling and Coding?
If your operation is currently labeling by hand or manually writing lot codes, automation can significantly reduce labor while improving consistency and traceability. In most cases, labor savings alone allow the equipment to pay for itself within a few months.
Pro Pack Solutions offers equipment testing with your containers and labels to ensure the right solution is selected before equipment is purchased.
Contact Pro Pack Solutions to discuss your containers, labels, and coding requirements.
(770) 554-1187
