A Guide to Product Reworking

What is reworking?

Reworking is taking packaging or products that have got damaged or been compromised in some way meaning they are not fit for sale, and fixing the problem so that they can be sold.

It covers all sorts of different work, from simply relabelling when a printing error has occurred to working direct on a product, for example our team has sewn up a large batch of dolls by hand before.

An example of a recent reworking project:

We recently reworked eight full lorry loads of bed linen for a large UK retailer, where the factory had used labour and had not been too diligent in sealing the packs correctly. We also QC checked the items and added new barcodes as required.

What kind of problems can be solved by reworking?

By it’s nature, reworking is a flexible service customised to the specific problem you have so there aren’t any major limitations on what can be reworked. Reworking is often manual and requires contract packagers with the experience and innovative thinking to get around a problem. Some examples of reworking projects that we have completed include:

  • Rearranging gift sets that have become disorderly or out of place.
  • New barcode application, if there is an error with the current barcode
  • Sewing in of labels (for example, we hand-sewed new tabs into socks)
  • Cleaning and re-shrink wrapping step ladders
  • Re-boxing garden furniture sets that were too heavy in their original boxes. We separated the sets from one carton to three.
  • Changing bottles of cola from a twin set to single products.
  • Cleaning contaminated packaging and sorting it from unsaleable goods
  • Removing inaccurate ink jet codes and replacing them with correct ones
  • Receiving stock from multiple locations and re-packing to make suitable for either UK or overseas clients.
  • Knitting work

And a lot more.

Is everything done by hand?

A lot of rework is hand assembly, yes. Sometimes coding and labelling can be automated and tasks that involve wrapping can be done by machines.

Is it expensive to get something reworked? Is it more cost-effective to simply remake or repackage the product?

Reworking is not always expensive, but it can be critical to ensuring a product is meeting legal requirements or regulations, or to ensure that is actually saleable in terms of aesthetics or other considerations.

Ultimately, it is down to the client to decide what is more cost-effective. Sometimes, if an imported good has problems the original factory will help with rework costs or do it themselves. However this can create transportation costs.

How long does it take to rework a product or packaging?

Job size and quantities involved can influence job length. We rework from a single or part pallet load, to multi-pallet and multi-lorry consignments.

Find out more

Find out more about our reworking services here.

Find out more about hand assembly here.