Why We Expanded
By 2021, monthly capacity was capped at 200,000 units and peak-season lead times slipped. The new facility unlocked 500,000+ units per month.
What the New Floor Layout Includes
Automated Die Cutting
High-speed Bobst die-cutters replaced manual cutting, reducing setup time from 2 hours to 15 minutes.
Inline Foil Stamping
Cold foil unit integrated with the printing press for consistent registration across long runs.
Dedicated QC Room
A climate-controlled inspection room with AQL 2.5 sampling, light booths for color verification, and drop-test rigs.
The Effect
Lead times shortened from 25 days to 15-20 days, and our defect rate dropped from 2.8% to under 1.2%.
