DRS label and barcode changeover plan for drinks lines

Freeze the affected product matrix

List each product, container material, volume, pack size, destination and current packaging code. Identify shared labels or cans that cannot be changed independently without affecting other markets.

Assign a new material code and controlled effective date for every changed item.

Prove artwork and machine compatibility

Check scheme mark, barcode or 2D-code location, statutory text, date-code area and label dimensions. Trial the production reel or printed container at normal speed with wet, cold or high-gloss conditions where relevant.

Verify label application, scan performance, code data, camera inspection and reject action.

Plan stock run-down and segregation

Count current packaging and finished-goods stock, forecast run-out and decide how unavoidable residual stock will be handled. Keep old and new material physically and digitally distinct.

Use line-clearance records at each transition. Verify hoppers, label reels, coder recipes, rework areas and partly used materials.

Reconcile the first production campaigns

For the first runs, reconcile material issued, good production, rejects, samples, rework and finished stock. Investigate any mismatch between code records and physical counts.

Retain first-off samples and verification reports with the artwork approval.

Information to prepare

• Approve the in-scope SKU register
• Create new controlled packaging codes
• Complete production-speed print and scan trials
• Set line-clearance and obsolete-stock controls
• Train operators on visual and scanner checks
• Reconcile material and good-container counts
• Retain first-off and approval evidence