Case Study: Optimizing Carton Printing & Labeling for a Global Manufacturing Client

Revolutionizing Industrial Packaging: How One Manufacturer Saved $300K Annually with Buskro’s Advanced Printing & Labeling Solution

In today's fast-paced manufacturing environment, operational efficiency and managing waste are critical. A global industrial manufacturer, facing inconsistent package processing across a diversity of systems, high production costs, excessive waste, found an innovative partner in BUSKRO. By implementing a state-of-the-art printing and labeling solution, they achieved savings of $300,000 annually, with a return on investment (ROI) in just six months. Here’s how Buskro’s technology transformed their packaging processes and helped them meet global standards while driving significant financial benefits.

The Challenge: This manufacturer, responsible for producing high-precision industrial metal components, was struggling with several packaging inefficiencies across its facilities:

1. Inconsistent Branding and Labeling: 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.
2. Regional Compliance Requirements: The client desired uniformity of branding including anti-counterfeiting measures, while maintaining efficiency and common processes across multiple locations worldwide.
3. High Operational Costs: 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.
4. Interfacing with MRP system. The client required that the systems be connected with their MRP system to manage workflows and improve seamless data exchanges and communication.

Buskro's Solution: To address these critical issues, BUSKRO provided and implemented a customized, high-efficiency printing and labeling solution that included:

1.?????? Modular Transport System (MTS): 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.

• Comprised of Atlas and Aurora print technologies with 2.55” and 5.10” print modules

2.?????? High-Resolution UV Print Heads: 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.

3.?????? Automated Error Handling and Workflow Management: 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.

4.?????? Compose IQ Workflow Software: 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 Results: After the system was installed and operational, the company experienced significant improvements in efficiency and cost savings:

• Standardization Across Global Facilities: 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.
• Operational Efficiency & Cost Savings: 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.
• Improved Production Speed: 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.
• Six-Month ROI: 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.

Buskro’s advanced printing and labeling solution didn’t just solve the company’s immediate challenges—it transformed their entire packaging process.

By automating key steps, standardizing output, and optimizing workflows, the company realized a six-month ROI. This partnership demonstrates the long-term value of investing in automation and innovation for global manufacturers.