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When a leading private label manufacturer needed to update canister labeling and promotional tray packaging for a club store infant formula product, the project presented was more than standard relabeling. The project’s unique canister design (in size and shape) required a custom engineered production solution, while a high volume of product with 37 individual product batches demanded careful production planning, line changeovers, and batch traceability.
Praxis Packaging Solutions designed, built, and implemented a custom automated rework line in less than four weeks. From testing and engineering through relabeling, tray replacement, and final shipment, the team delivered a complete turnkey solution that allowed the customer to salvage valuable product, meet retail requirements, and avoid unnecessary waste.
Objective
Develop a high-volume rework solution capable of updating club store packaging for infant formula while maintaining batch integrity, accommodating a uniquely shaped container, and meeting an aggressive customer deadline.
SOLUTIONS
Custom-Engineered Production Line
Because of the container’s unique size and geometry, traditional packaging equipment could not efficiently process the product. Praxis engineers developed a custom automated solution specifically designed for the canister, allowing the project to move from concept to production in just weeks.
The custom line provided the speed, consistency, and handling required to efficiently process a large volume of product while protecting package integrity throughout the rework operation.
Complex Multi-Batch Rework
Managing numerous batch transitions while maintaining production efficiency required detailed planning and disciplined execution. This project involved 37 separate production batches, requiring frequent line adjustments and careful management of product segregation and traceability. Praxis coordinated each batch through a controlled process that included:
- Removing canisters from existing club trays
- Disposing of obsolete packaging
- Removing outdated labels
- Applying new compliant labels
- Building and gluing new retail-ready club trays
- Repacking finished product
- Palletizing for shipment
Fast Turnaround from Start to Finish
The accelerated onboarding process, combined with rapid engineering and production startup, enabled the customer to meet its timeline without sacrificing quality. Within four weeks, Praxis:
- Received test product
- Engineered and validated the custom solution
- Received production inventory
- Completed the full rework operation
- Shipped finished product back to the customer
Conclusion
Praxis transformed a complex packaging challenge into a successful product recovery effort. By rapidly engineering a custom production solution and executing a large-scale, multi-batch rework project, the team enabled the customer to update club store packaging without scrapping valuable inventory.
The result was a fast, efficient, and scalable solution that preserved product value, ensured packaging consistency, and delivered finished goods on schedule.
Services Provided
Brite Stock Labeling, Labeling, Rework & Inspection, and Secondary Packaging
100%
Product Salvaged instead of scrapped
4 Weeks
From Onboarding to Customer Delivery
37
Individual Product Batches
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