End-to-end production of 11-component activity kits: printing, sourcing, assembly, QC, and poly-bagging — with 100% retailer QC pass rate.
A children's education company needed 100,000 activity kits for a national retail launch. Each kit contained 11 components: 8 printed items (activity books, sticker sheets, coloring pages, instruction cards, retail header cards) plus 3 non-printed items (crayons, stencils, storage pouch). The kits had to be individually assembled, quality-checked, and poly-bagged with retail-ready header cards. The client's previous kitting vendor had a 7% defect rate on component accuracy, leading to retailer chargebacks.
We managed the entire production chain in-house: all 8 printed components were produced on our offset and digital presses. Non-printed items (crayons, stencils, pouches) were sourced through our vetted vendor network. Assembly was handled on our dedicated kitting line with a station-based workflow — each station responsible for specific components with visual verification at every stage. A 100% visual QC checkpoint verified component completeness before poly-bagging with custom retail header cards. Delivery was staged in 3 waves over 6 weeks to match the retailer's distribution schedule.
100,000 kits were delivered across 3 waves, all passing retailer receiving inspection on first submission — a 100% QC pass rate with zero chargebacks. The kits were placed in 800+ retail locations and generated $2.4M in retail revenue for the client in the first quarter. The client has since expanded the program to 3 seasonal kit variations produced quarterly.
“Our production partner handled everything — printing, sourcing, assembly, and shipping. Zero defects on 100,000 kits. That kind of reliability is rare in promotional production.”Director of Operations — Children's Education Company
Get a free consultation to discuss your project requirements.
Get a Free QuoteCustom stickers, magnets, badges, kitting, and retail-ready merchandise.
Read more →High-volume print production for fast-moving consumer goods brands.
Read more →How a national retailer unified packaging across 2,400+ stores.
Read more →Compare printing methods, specs, and materials side by side.
Read more →Get a custom quote for your print project within 24 hours.
Read more →