The company’s packaging processes varied from facility to facility, resulting in inconsistent branding and non-uniform labeling, which leading to confusion and potential compliance issues.
The company’s packaging processes varied from facility to facility, resulting in inconsistent branding and non-uniform labeling, which leading to confusion and potential compliance issues.
Manual oversight, high-setup costs, re-work due to errors, and inefficient workflows were driving up costs and slowing down production. This resulted in higher labor expenses and unnecessary material waste.
The client required that the systems be connected with their MRP system to manage workflows and improve seamless data exchanges and communication.
Buskro’s advanced modular system was configured to handle a wide range of package sizes, feed and transport KDF corrugate cartons, add both variable data and anti-counterfeit labels in the form of barcodes and human-readable print, and at the output inspect, verify, divert, and re-order wasted products. This drastically cut down on manual intervention, slashing setup times and allowing the company to redeploy workers for higher-value tasks. Solution comprised of Atlas and Aurora print technologies with 2.55” and 5.10” print modules.
Utilizing BK2540 Aurora UV inkjet heads, the Buskro printer delivered precision printing for both the security labels and carton panels. The high print resolution (400 X 600 DPI) ensured crisp, highly legible, high-grade barcodes and product information, facilitating and ensuring barcode readability, reducing errors and improving accuracy.
The Buskro solution included barcode scanners, forming a close-looped system to print and inspect the barcodes for legibility, error detection, and rework. Any printed cartons failing inspection were automatically diverted for reprocessing, eliminating costly manual inspections and rework.
Compose IQ, Buskro’s well proven, reliable software tool tasked with tracking and monitored individual cartons from start to finish, coordinated the personalization activities and through automation
Buskro’s advanced modular system was configured to handle a wide range of package sizes, feed and transport KDF corrugate cartons, add both variable data and anti-counterfeit labels in the form of barcodes and human-readable print, and at the output inspect, verify, divert, and re-order wasted products. This drastically cut down on manual intervention, slashing setup times and allowing the company to redeploy workers for higher-value tasks. Solution comprised of Atlas and Aurora print technologies with 2.55” and 5.10” print modules.
Utilizing BK2540 Aurora UV inkjet heads, the Buskro printer delivered precision printing for both the security labels and carton panels. The high print resolution (400 X 600 DPI) ensured crisp, highly legible, high-grade barcodes and product information, facilitating and ensuring barcode readability, reducing errors and improving accuracy.
The Buskro solution included barcode scanners, forming a close-looped system to print and inspect the barcodes for legibility, error detection, and rework. Any printed cartons failing inspection were automatically diverted for reprocessing, eliminating costly manual inspections and rework.
Compose IQ, Buskro’s well proven, reliable software tool tasked with tracking and monitored individual cartons from start to finish, coordinated the personalization activities and through automation
The new system ensured consistent branding and labeling across multiple facilities worldwide, reinforcing brand identity while improving efficiencies tied to non-compliance and rework processes.
By reducing waste, minimizing manual intervention associated with rework, and streamlining the overall workflow processes from data/job preparation to job completion, the company was able to realize a 6-month ROI. Additionally, through reduced setup and inspection processes, significant labor hours were freed up, further contributing to cost reductions.
With process efficiencies net throughput was higher, with less labor requirements, improved job coordination, and greater job progress visibility, leading to significant additional hours of operational efficiency savings.
Thanks to the significant cost savings and increased productivity, the company achieved a full return on their investment in just six months—a remarkable achievement for such a large-scale operation.
