“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:
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.
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:
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.
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:
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.
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:
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.
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:
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.
Meeting or beating expectations is achieved by adhering to compliance demands in a well-defined process (Brand Vs. Regulatory). Your process should be proactive when faced with change in compliance demands that threaten to disrupt the cycle. Finding solutions quickly is key in the race to market.
Setting expectations early are key to an all-around successful product launch. This includes, not just the hard-cost (the money), but outlining what your soft cost are too, re: time-to-market, staff, marketing, legal, etc.
How you purchase or hire for print, material spec, or layout all play a factor in your project timeline and cost. Make sure that your Process Map is working for you, not against you. For example, an internal review of our Client’s workflow identified several areas that could be streamlined or removed. Once the changes were implemented their order lead-time was reduced by 19 days or 63% on every order!
Aligning with experienced vendors quickens workflow … Find suppliers who can offer value to your process. They should carefully listen and create a process map to ensure compliance to your individual needs. Process optimization starts with listening, then creating a workflow that can be actively managed by both parties to ensure quality throughout the manufacturing cycle.
Beating expectations is achieved with an organized and empowered staff that can layout and adhere to a well-defined process. Your suppliers should mirror this sentiment and become an extension and a confidant to your team. Look to partner in this capacity for best results and practices – after all, they are the experts in what they do.
Accurate price quotes come from accurate specifications. Implement a collaborative process from start to finish between your team and your suppliers. This will allow for conversation to alleviate any guesswork and ultimately help keep the project on budget and the initial expectations met.
When market conditions shift take solace in your resources. Go back to your well-trained and informed team and brainstorm for innovative solutions. Include your suppliers in the conversation; they may have experienced the change in market before and can help navigate you through the change in process.
Soft costs are real costs. Taking time to assess them, although harder to quantify, may result in overall cost savings benefits such as: reduced time-to-market, cost avoidance, lost profit avoidance, improved employee morale, enhanced image for the organization and more.
Plan copy length to take advantage of standard paper sizes. This will be a cost savings and will allow for a much faster turn-around on material compared to a custom mill order.
Getting your printer involved early in the planning stages, particularly regarding the flat and folded size and thickness of the final product, often times leads to cost savings and quicker time-to-market.
Two Ply Label
A large dental supply company sold a specific product in the United States. The product was sold in relatively small amounts and the label coved virtually the entire surface area of the jar. The company decided to sell the product in Canada as well. The problem they faced was now the label had to contain both English and French.
Mercantile Press was asked to develop a solution. We listened to the customer and designed a 2-ply label that would accommodate both English and French. The label consisted of a pressure sensitive paper base with a single paper leaf that was film laminated and die cut. The end user simply has to pull the tab and open the label exposing the French on the inside.
The result was a label that fit in the exact area of the original English only version while allowing them to be compliant in adding the French content for sale in the Canadian market.
Magnet Sleeve Labels
A large chemical company developed a system that would allow a device to blend various products into custom blended products for niche applications. The device used sensors that would detect small magnets that were molded into a high density polyethylene container. The problem with molding the magnets into the HDPE container was twofold.
First, the process was extremely expensive. This was now a specialized container that was not only more expensive to manufacture than a conventional HDPE container, it also considerably increased 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.
Mercantile Press was called in to see if we could offer a better solution. After listening to the customer, we proposed a magnet label where a standardize template of numbered circles would be printed on the back of the label. This template would be common across all product lines. Next, Mercantile Press would apply a “glue dot” on the specific number configuration of that product. 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 savings for the customer, the magnetic label can be removed and the container can be processed for recycling.
3rd Party Workflow Process Improvement
Mercantile Press not only produces labels and supplemental labeling for a major agrichemical company, they also provide typesetting and layout services for packaging that is printed by various other suppliers. In an effort to reduce the lead-time for corrugated cartons, multiwall bags and sleeve labels, Mercantile Press was asked to participate in meetings with these suppliers because of our “outstanding ability to meet delivery requests”. The goal was to mirror the process Mercantile used to significantly reduce the time an order takes to manufacture and deliver.
As a third party to the process, Mercantile Press was able to apply many of its internal processes involving
order review and entry through proofing and art approval. Although this process was a bit challenging for the participating companies, the results were significant.
The corrugated carton company was able to reduce the order lead-time by 6 days or 25%. The most significant savings was with the multiwall bag manufacturer. Mercantile Press helped them reduce their lead-time by 19 days or 63%! And these savings are not just for one order but for every subsequent order placed after these process improvements were implemented.
To counteract the chance of a costly mistake found on-press (or after), proofread from a hard-copy proof. Often times this provides a different look rather than the redundancy of electronic revision rounds. Forcing your eye to see it from a new perspective will allow for a clean read.
Sometimes terminology can be tricky. The old saying “a picture is worth a thousand words” can be useful. Folded samples, pictures or technical renderings are often helpful in communicating exactly what you are trying to achieve.