Colbert Packaging, Kenosha, WI, USA, a leader in the pharmaceutical and healthcare packaging industry, needed a robust solution to ensure defect-free shipments, improve operational efficiency, and maintain compliance with industry standards. To address these challenges, the company integrated the LearyVIEW Print Solution, powered by EyeC and W. H. Leary, into its production processes. This case study explores how this investment transformed Colbert Packaging’s quality control, efficiency, and market positioning.
The challenge
Colbert Packaging sought a vision system that could:
-
Detect and eliminate defective products before shipment
-
Prevent costly returns from overseas customers
-
Meet stringent industry requirements for defect scanning and serialization
-
Improve operational efficiency through automation
-
Give them an advantage in the pharmaceutical packaging market
Nick Stober, Director of Quality Systems and Compliance at Colbert Packaging, highlighted, “We needed a system that could scan products before shipment within our company network. It is especially important before a shipment makes a journey overseas, to ensure defects are caught early and prevent costly returns.”
With pharmaceutical and healthcare customers requiring precise defect detection, the need for a reliable vision system became crucial.
The solution: LearyVIEW Print Solution with EyeC inspection technology
Colbert Packaging partnered with W. H. Leary to implement the LearyVIEW Print Solution due to its:
-
Seamless integration with existing Leary gluing systems
-
Technologically advanced defect detection powered by EyeC’s 100% inspection system
-
Compact size, requiring only 18 inches of additional space versus other solutions needing 6–8 feet
-
Strong technical support from both W. H. Leary and EyeC and ease of installation
Wanda Speer, Marketing Manager at Colbert Packaging, included, “By scanning all cartons, we are mirroring what our customers are doing. That is incredibly valuable to them.”
Key benefits and outcomes
Competitive advantage and business growth
One of the unexpected benefits was its impact on sales. “We’ve used our system as a marketing tool,” said Stober. “It has helped us win business that we might not have secured otherwise.” Large pharmaceutical companies have chosen Colbert Packaging due to its superior inspection capabilities.
Operational efficiency and cost savings
Prior to implementing the vision system, Colbert Packaging, like many other carton producers, would run the risk of having to discard entire batches due to an inability to pinpoint specific defects. Stober explained, “In the past, it took a team to sort quality defects. Now, with the LearyVIEW Print inspection system, we utilize technology and automation to verify quality standards are achieved.”
The automated inspection system also allows Colbert to refine upstream processes. For example, adjustments were made to the printing process for certain customers to eliminate recurring defects, leading to significant efficiency gains.
Error prevention and continuous improvement
The system acts as a learning tool, enabling Colbert Packaging to identify defects early and implement corrective actions. Jeff Bates, National Sales Manager at W. H. Leary, noted, “If you catch something in the middle of your process, you can correct it immediately, avoiding further waste.”
By eliminating the need for human sorting, the system ensures accuracy, speed, and consistency—factors critical to pharmaceutical packaging compliance.
Return on investment (ROI) and sustainability
Wanda Speer explained that the investment has not only improved efficiency but also attracted new business. “Having these systems in place has directly contributed to new business opportunities, both from existing and new customers.”
From a sustainability perspective, reducing waste, minimizing rework, and maximizing workforce efficiency align with Colbert Packaging’s long-term goals.
Strong technical support and future expansion
Colbert Packaging was highly satisfied with the technical support provided by Leary and EyeC. Stober explained, “Leary’s service response time is exceptional. With other vendors, we could wait up to two weeks for technical support, but with Leary, we typically receive assistance within 24 hours.”
Looking ahead, Colbert sees a future where every folder gluer in its facility is equipped with a LearyVIEW with EyeC vision system. “I think the market is heading in that direction,” said Stober. “As we look at our sustainability program, reducing rework and waste contributes to additional ROI.”
Conclusion
The implementation of the LearyVIEW with EyeC Print Solution has significantly enhanced Colbert Packaging’s operations. By ensuring defect-free shipments, improving efficiency, and providing a competitive edge, the system has proven to be effective. With strong ROI and continued support from Leary and EyeC, Colbert Packaging is well-positioned to maintain its leadership in the industry.
Through its commitment to quality and innovation, Colbert Packaging has set a new standard in pharmaceutical and healthcare packaging, demonstrating the power of advanced inspection technology in modern manufacturing.