How a Children's Brand Produced 100K Activity Kits Generating $2.4M in Retail Revenue

End-to-end production of 11-component activity kits: printing, sourcing, assembly, QC, and poly-bagging — with 100% retailer QC pass rate.

100,000

Kits Produced

Components Per Kit

100%

Retailer QC Pass

$2.4M

Revenue Generated

[ THE CHALLENGE ]

The Challenge

A children's education company needed 100,000 activity kits for a national retail launch. Each kit contained 11 components: 8 printed items (activity books, sticker sheets, coloring pages, instruction cards, retail header cards) plus 3 non-printed items (crayons, stencils, storage pouch). The kits had to be individually assembled, quality-checked, and poly-bagged with retail-ready header cards. The client's previous kitting vendor had a 7% defect rate on component accuracy, leading to retailer chargebacks.

[ OUR SOLUTION ]

Our Solution

We managed the entire production chain in-house: all 8 printed components were produced on our offset and digital presses. Non-printed items (crayons, stencils, pouches) were sourced through our vetted vendor network. Assembly was handled on our dedicated kitting line with a station-based workflow — each station responsible for specific components with visual verification at every stage. A 100% visual QC checkpoint verified component completeness before poly-bagging with custom retail header cards. Delivery was staged in 3 waves over 6 weeks to match the retailer's distribution schedule.

Capabilities used:Promotional & DIY Goods Custom Print Production

[ THE RESULTS ]

The Results

100,000 kits were delivered across 3 waves, all passing retailer receiving inspection on first submission — a 100% QC pass rate with zero chargebacks. The kits were placed in 800+ retail locations and generated $2.4M in retail revenue for the client in the first quarter. The client has since expanded the program to 3 seasonal kit variations produced quarterly.

“Our production partner handled everything — printing, sourcing, assembly, and shipping. Zero defects on 100,000 kits. That kind of reliability is rare in promotional production.”

Director of Operations — Children's Education Company

[ MORE SUCCESS STORIES ]