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Wrap labels don’t work so well when you have a lot of information

Wrap labels don’t work so well when you have a lot of information

“Wrap labels” have been used for OTC medications and other applications for years. It enables a manufacturer to achieve and maintain regulatory compliance on a relatively small container. A contract packaging company recently came to us seeking a different solution due to an ever-increasing label content. Additionally, the contract packager was looking to overcome some specific challenges with the current label construction including speeding up the application and multilingual capacity.

This combination of factors meant that the content was best suited to a booklet form rather than a continuous label. However, the challenge in constructing this type of label for a vial of this size was the small circumference of the container. Typically, 2-ply or multiply labels do not work well on this type of container because the various plies extend to different lengths when applied or wrapped around the container. This creates a label that looks if it has not been applied correctly and reduces consumer confidence in the product.

The secret is in the cutting

After carefully listening to the client, our solution was to use our unique manufacturing process to die cut the label in-line both before and after printing. This allowed the label to wrap securely around the vial while fitting well to the surface. It is easily opened and re-sealed.

By using a supplier with unique, specialized equipment, the company was able to provide more content than normal, despite the small size of the vial. It also allowed variations for special promotions.

Before finalizing a label solution for your product, here are three issues for you to reflect on:

  • Consider what information you require on your label. Will it always be the same or do you require variable content for coupons or similar?
  • Check that your supplier is used to producing a wide range of label types for vials. Ask what new ideas they can demonstrate to you
  • Consider the best type of label for your content. Does it require a multiply label? Will your content be better displayed using a multiply, onsert or booklet label?

As a result of the exercise the label was well received by the pharmaceutical company and by its contract packaging supplier. The company plans to launch more products in this format now that the labelling challenges have been overcome.

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What do you do when there’s too much information for your label?

What do you do when there’s too much information for your label?

A large US dental supply company was expanding its market into Canada. One of their products is packaged in a relatively small volume and in a small jar. The label covers virtually the entire circumference of the jar, with the English copy utilizing almost all the label surface. The problem they now faced was that the label would have to be multilingual containing both English and French.

Where Do We Begin?

Before production could begin, the following issues needed to be satisfied:

  • Compliance
  • Content/languages needed
  • Brand identity
  • Ease of use
  • Constraints of filing/packaging lines

And The Results Are In! – We created a multi-lingual label that fitted in the exact area as the original English only version

The result was a multiply multi-lingual label that fitted in the exact area as the original English only version. It ensured the product was compliant for sale in the Canadian market by adding the French content, with clear indicators on where to read this. Since English was still the primary panel, overall brand identity was maintained.

By using the right supplier, the company was able to solve a challenging content issue on a small package.

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Auto Applying Labels for Large Drums? Yes, it’s possible!

Auto Applying Labels for Large Drums? Yes, it’s possible!

How one company saved on large drum label application

A chemical company wanted to automate the hand applying of large drum labels for all their product offerings. They began working with a label applicator manufacturer to engineer a custom-built device that would apply a roll label up to 25” wide.  Not only was this proving to be a difficult task, but the capital expenditure for this custom applicator was also significantly more expensive than a standard build. In addition to the capital costs, providing relatively short run labels with a 25” width was also proving to be and expensive proposition. Additionally, large roll handling was going to be an issue at the application site.

Let’s look at this from a different perspective

A new proposal was brought forward to divide the large 25” label into 2 smaller labels. This made label handling much easier. Since much of the label content was common along several product lines, creating one common label for all the products and one product specific label would be the best solution. These labels would be a common size and format so shorter label orders could be run in a cost-effective manner.

The other significant advantage to this concept was the fact that the company could purchase two standard application heads without re-engineering the current equipment. By purchasing two standard label applicators, they could apply two labels simultaneously on the production line. This saved the company significant startup capital, and the new label specification could be produced in a timely fashion at a reasonable cost.

Seeking the input from additional suppliers really paid off

By gathering input from other stakeholders and suppliers in the process, the company was able to solve a problem utilizing standard, available equipment saving them time and money.

Here are three first steps to take if you are considering moving from hand applied to auto applied labels:

  • Talk to whoever will be applying labels to understand what works best for them
  • Share the specification of their machine with your label supplier
  • Talk to your label supplier about the different labelling options

The result was they no longer tie up personnel to hand apply labels. They can now cost effectively apply labels semi-automatically that are easy to handle at a cost that is significantly less per label than the original process.

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Iron and HDPE Don’t Mix

Iron and HDPE Don’t Mix

Finding a solution to a magnetic problem

Recently I was invited to a meeting to discuss a particular problem a client of ours was having with the high-density polyethylene container jugs for their custom blended products. The client developed a system that would allow a device to mix various ingredients into custom blended products for niche applications. The device used sensors that would detect small magnets that were molded into a HDPE container. The device senses the position of the magnets, measure and dispense the precise amount of each ingredient relative to the total amount of the final product needed for application.

The problem they were facing is the magnets were molded into the jug. The drawback to molding the magnets into the HDPE container was twofold. First, the process was extremely expensive. This was now a custom container that was not only substantially more expensive to manufacture than a conventional HDPE container, but it also increased considerably to delivery lead time beyond the standard container.

The second issue facing this design was that the container was no longer recyclable and therefore had to be disposed of in a conventional landfill. From an environmental standpoint, this was not acceptable.

Things changed when we added glue

After some discussion, we came up with a unique solution: Affix “glue dots” to a predetermined sequence from a standardized template of numbered circles printed on the back of the label. This sequence determines the amount of each ingredient dispensed into the jug. The labels are then shipped to the applicator where the liner is removed from the glue dot and a small magnet is applied to the label. Since these were niche products manufactured in relatively small quantities, the process proved to be cost effective. In addition to saving time and money for the client, the magnet label could be removed which meant the container could now be processed for recycling.

Workflow reviews can drastically reduce costs

The company was able to solve a huge dilemma by simply inviting other people who might not normally be involved in the process to look at the problem. This saved the company significant amounts of time and money. One help was involving the label manufacturer at the beginning of the process.

Here are three ways to start solving similar challenges:

  • Review who else might be able to contribute good advice
  • Set up a group brainstorm
  • Prototype new ideas for testing

The Result: The company was able to expand its presence in a market segment without the cost and lead time of a custom HDPE container.

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How to Reduce Label Lead-Times by Over 60%

How to Reduce Label Lead-Times by Over 60%

Time = Money

Every business is in a constant quest to increase efficiencies and reduce costs. In the case of a major US agricultural products company, they were in a quest to reduce lead-times and increase efficiency for corrugated cartons, multiwall bags, and labels by looking for ways to improve the artwork approval process. They wanted to respond quickly to customer orders while waiting for regulatory approvals. Once it cleared the approval process, it was critical to maintain accurate content versioning throughout the production for all the packaging components.

This is where DAM comes in

Develop a digital asset management system that will improve communication and efficiencies from artwork creation to distribution for print production therefore significantly reducing the order lead time.

Go ahead: Take the first step

The first step in developing a digital asset management system is to define the stakeholders. This includes design agencies, brand managers, marketing, legal and regulatory team members as well as vendors responsible to produce the various packaging elements. Next, a clearly defined process must be written indicating the steps needed from originating copy to signoff and print. Once completed, there are a variety of digital asset management systems that can be evaluated and implemented to automate the processes your team has created.

Reducing lead time is a lot easier than you may realize

Here are three easy things you can do to help get you started. Some of these you may already be doing:

  • Measure the time taken between each step and throughout the entire process. You can begin to see the impact on your business.
  • Talk to your current vendors and ask if centralized digital asset management will enhance your current process. They may already be doing something similar, and they could be a useful resource.
  • Reference industry associations or pier groups for “best practices” regarding the subject.

We have seen lead times reduced by as much as 63%!

As a result of implementing a digital asset management system, order lead time for this company was reduced by as much as 19 days! Additionally, the ability to get there products to their distributors faster proved to be the biggest asset.

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