Secondary Packaging Case Study: Cartoning And Kitting

Rapid scaling met urgent public health demand when a pharmaceutical company needed to bring an OTC COVID-19 testing kit to market—fast. A dedicated production line was designed and fully operational in under five days, combining advanced equipment with a workforce of more than 200 employees. The result: over 20 million high-quality kits assembled in just eight months, with peak output exceeding 100 kits per minute.

A structured approach to quality control ensured consistency across complex, multi-component assemblies, while a two-shift workforce enabled both speed and flexibility. This effort made self-testing more accessible, removing common barriers like wait times and limited availability.

Explore how rapid line setup, scalable labor, and tightly managed processes can accelerate time to market without compromising quality.