Based in Nidda, Hesse, variopack Lohnfertigungen GmbH has specialized in contract packaging for over four decades and is now one of Germany’s leading full-service co-packers, serving clients in the food, pharmaceutical, cosmetics, and household hygiene sectors. With approximately 250 employees, over 100 modular packaging units, and more than 40 separate production rooms, the company offers a high degree of flexibility to meet a wide variety of customer requirements. Certifications such as IFS Food Version 8 at a higher level, the official manufacturing license pursuant to Sections 13(1) and 72(1) of the German Medicines Act, and an organic certification underscore the company’s high-quality standards. Especially in this regulated environment, secure and traceable testing processes play a central role.
The Limits of Manual Inspection
As a co-packer, variopack works daily with a wide variety of packaging designs, language versions, and customer-specific requirements. Visual inspection became increasingly challenging, particularly when dealing with similar layout variations or minor text changes. In some cases, discrepancies in the print image were difficult to detect, and the previous manual inspection process proved to be time-consuming and heavily dependent on the concentration and experience of the employees. The risk that print image deviations would be discovered too late - or, in the worst case, only after delivery - was unacceptable. Added to this was growing regulatory and economic pressure: With stricter requirements for documentation, traceability, and the speed of approval processes, it became clear to variopack that the existing inspection processes needed technical support in the long term to reliably minimize risks and meet rising regulatory requirements.
How Technology, Ease of Use, and Support Shaped the Decision
The company was looking for a solution that could reliably compare approved print data with the materials delivered. “When making our selection, it was important to us that the new system not replace the technical assessment performed by our employees but rather support them in conducting a structured and traceable inspection,” explains Christian Heilmann, Authorized Signatory for Process Control & IT at variopack Lohnfertigungen GmbH. The team first analyzed the market and compared various providers and solutions for print image inspection. In addition to technical capabilities, the focus was primarily on ease of use, flexibility, and integration into existing processes. Equally important were reliable support, professional on-site installation and training, as well as compliance with the high requirements of the GMP environment. Additional discussions with suppliers and industry partners helped identify solutions that had already proven themselves in practical use. In a direct comparison with another German provider, the decision was ultimately made in favor of the EyeC Proofiler 600 DT from EyeC GmbH. The ISO-compliant barcode inspection and the ability to measure Braille relief were particularly decisive factors. In addition, EyeC impressed us with its combination of specific functionalities and the comprehensive package of technology, consulting, and personalized support throughout the entire implementation process. “We found the close and straightforward collaboration with EyeC to be particularly positive; from the very beginning, it was highly professional, practical, and solution-oriented,” the process expert said of the collaboration. “Overall, we had the impression that EyeC not only delivers the right technology but also provides reliable support for its implementation in day-to-day operations.”
Smooth Integration into Production Workflows
Through Dedicated On-Site Support With the EyeC Proofiler 600 DT, variopack introduced a scanner-based inspection system for the automated quality control of printed materials. The solution combines high-resolution scanning technology with intelligent inspection software, enabling objective and reproducible verification of text, graphics, colors, and codes. Printed products are digitally compared with approved print PDF references. In addition to checking content accuracy, the system also monitors print quality and reliably detects even the smallest deviations. Items inspected include films, folding cartons, labels, boxes, and package inserts.
With close, reliable support from the EyeC team, the system was quickly integrated into our daily production operations. variopack particularly highlights the quality of the close collaboration with the various contacts at EyeC. “Mr. Hauswald and his team understood our requirements very well from the start and provided us with expert guidance throughout the entire process. When it came to quality-related issues, we were able to rely on Dr. Schwarz’s in-depth expertise, particularly in the demanding GMP environment, and the commissioning and training provided by Mr. Manegold were also practical and perfectly tailored to our internal processes,” emphasizes Christian Heilmann.
Early Error Detection for Streamlined Approval Processes
Since introducing the EyeC Proofiler 600 DT, variopack has been conducting an average of 10 to 20 inspections per day. The checks are primarily conducted on a random basis to detect potential print image deviations early on and to ensure documented approval. The results show significant improvements in several areas. By clearly defining acceptance criteria, print deviations are reliably detected, and defective material is identified early on. This effectively prevents costly rework or potential recalls. At the same time, automated inspection significantly reduces the effort required for manual visual inspection, allowing employees to focus more on technical evaluation rather than performing time-consuming visual comparisons. Approval processes have also been noticeably accelerated, as inspections can be conducted directly on-site and within a short time. This shortens turnaround times and supports faster order processing. In addition, all inspections are documented in a reproducible manner, enabling variopack to reliably meet both internal quality standards and regulatory requirements within the GMP framework. For the company, it is particularly crucial that the solution not only impresses technically but also tangibly simplifies and sustainably supports day-to-day work in quality management.
Driving Long-Term Quality Improvement Through Enhanced Reliability
For variopack Lohnfertigungen GmbH, the introduction of the EyeC Proofiler 600 DT was much more than just a technology project; it was a significant step forward in the further development of its internal quality processes. Today, the system is an integral part of the inspection and approval process and helps the company efficiently meet increasing demands regarding product variety, regulatory compliance, and documentation. “With the EyeC Proofiler 600 DT, we have established a smart solution that not only delivers today but can also reliably meet future requirements,” summarizes the authorized signatory. “At the same time, we view our partnership with EyeC as a crucial foundation for continuously improving our quality processes and responding flexibly to evolving market and regulatory conditions.”
Further information about variopack Lohnfertigungen GmbH at variopack.de