Client Background
A leading global food manufacturer's South China production base, specializing in condiment production with annual exports exceeding 5 million cases. Facing 40% YoY growth in export SKUs for 2024, their manual labeling process became a critical bottleneck.
Challenges
1. Manual labeling across 5 production lines operated at 30 bottles/min with labor costs accounting for 65% of total packaging expenses.
2. ±0.5mm precision requirement for curved surface labeling on flat plastic soy sauce bottles, with human error rate reaching 12%.
3. Frequent label changes for new SKUs causing 45+ minutes of downtime per line switch.
Solution
Deployed customized single-side surface labeling machine featuring:
• Dynamic surface compensation technology with AI vision achieving 98.7% first-pass yield.
• SanTuo’s self-developed non-stop label changing mechanism, truly realizing non-stop label change.
• Smart control system centralizing monitoring across 5 lines, boosting OEE to 89%.
Results
✅ 233% efficiency gain with 350 bottles/min per line
✅ Annual labor cost reduction of ¥3.6M with <14 month ROI
✅ 82% decrease in customer complaints
✅ Future-proof scalability supporting 50% SKU growth over 3 years
