Nearly 12,000 bottles saved through the application of covering labels

You have nearly 12,000 bottles that have already been produced, filled and packaged… but cannot be marketed due to a labeling defect.

Yet, you need to bring the products back to market within less than 5 weeks.

What can you do?

In this type of situation, the usual response is often to destroy the stock and manufacture it again.

At OVERPRINT, we explore another possibility: adapting the existing packaging.

Context

This is what happened to a French skincare laboratory: nearly 12,000 200 ml bottles, across two product references, were affected by air bubbles, particles and label alignment issues.

Two conventional solutions are considered: Destroying the stock and remanufacturing all the products, with an estimated lead time of 8 to 14 weeks or manually removing the defective labels and applying new ones.

The second solution is tested but proves incompatible with the volume to be processed and the technical constraints.

However, the client needs to return the products to the market within 5 weeks.

The challenge is therefore to find a solution that can save the existing stock, without destruction or complete remanufacturing.

Context

Our intervention

OVERPRINT receives 30 samples at its facilities to carry out a testing and qualification phase.

The tests show that removing the labels takes more than 5 minutes per bottle to eliminate adhesive residue. Given the volume to be processed, this method is not compatible with the required timeframe.

On one of the two references, removing and replacing the label also creates a visible interface effect between the label and the bottle.

OVERPRINT therefore chooses a different approach: not removing the existing label, but covering it completely.

A new covering label is developed using opaque white polypropylene film, with four-color printing and a matte soft-touch coating. The four BAG (Bons À Graver) are approved within one week.

To secure the application process, OVERPRINT also designs a dedicated positioning jig. This tool mechanically guides the operator and ensures highly accurate label positioning.

Production is then carried out at OVERPRINT's facilities, with 100% batch traceability maintained and quality control performed on every bottle.

Result

Thanks to this intervention:

-Nearly 12,000 bottles processed

-99.4% final yield

-0.57% net production waste

-More than 85% savings compared with destruction and remanufacturing

The time required to return the products to market reduced by more than threefold

We were therefore able to bring an already manufactured stock into compliance without destroying the filled bottles or undertaking complete remanufacturing.

Giving packaging a second chance

This case shows that non-compliant packaging does not necessarily have to be destroyed.

Before removing labels, destroying products or remanufacturing them, OVERPRINT first examines the possibilities for adapting what already exists.

Make OVERPRINT your first reflex: adapt before you destroy.

Contact

Contact us or request a quote

  • Phone

    +33 (0)4 97 21 00 97

  • Email

    contact@overprint.com

  • Address

    OVERPRINT FRANCE
    Les espaces de Sophia – Bâtiment O
    80 route des lucioles
    06560 VALBONNE FRANCE

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