How a National Retail Chain Saved 22% on a 2M-Unit Packaging Rollout

A national retail chain with 400+ store locations needed to launch new packaging within a 6-week window. The challenge was three-fold: exact Pantone color matching across multiple substrate types (coated, uncoated, and synthetic), coordination across 3 product categories with different packaging structures, and logistics that required phased delivery to regional distribution centers. Their previous supplier had been producing at Delta E > 3.0 with a 23% defect rate on in-store displays, causing visible brand inconsistencies across locations.

All 2 million units were delivered on schedule across 5 regional distribution centers. Color consistency measured at Delta E < 1.5 — well within premium brand standards. The gang-run optimization reduced per-unit costs by 22% compared to the client's previous supplier. The program has since expanded to quarterly production runs covering seasonal packaging refreshes.