Product reworking: what it is and how it benefits your product

This guide will explain what the product reworking process is, the activities associated with reworking and other frequently asked questions.

  • What is reworking?
  • What are some reworking activities?
  • What problems can be solved by reworking?
  • What are the benefits of outsourcing reworking services?
  • Is reworking done by hand?
  • Is it expensive to get something reworked?
  • What is the process when getting a package reworked?
  • How long does it take to rework a product or package?
  • Common ways packaging can be damaged
  • How to avoid product damage with the right packaging

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What is a reworking?

Reworking is taking packaging or products that have been damaged or compromised in some way, making them unfit for sale, and fixing the problem so that they can be sold. It requires a highly skilled and experienced team to ensure the product is reworked correctly.

What are some reworking services?

A rework covers several key activities such as:

  • Stickering
  • Security tagging
  • New price point application
  • Leaflet and carton changes
  • Barcoding
  • Shelf-ready packaging
  • POS display assembly and filling
  • Stickering
  • Cleaning

What problems can be solved by reworking?

By its nature, reworking is a flexible service customised to the specific problem you have so there are few limitations on what can be reworked. Reworking is often manual and requires contract packagers with the experience and innovative thinking to solve a problem. Some examples of reworking projects that we have completed include:

  • Rearranging gift sets that have become disordered
  • New barcode application if there is an error with the existing barcode
  • Sewing-in of labels (for example, we handstitched 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 fizzy drink bottles 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

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 not shown the diligence needed to seal the packs correctly. We also quality checked the items and added new barcodes as required.

What are the benefits of outsourcing reworking services?

Outsourcing your rework process can offer several major benefits over doing it in-house. The most common reasons for outsourcing reworking are:

  • Faster and more cost-effective
  • Skilled teams working on your products
  • Reduced storage space and costs
  • Stress-free
  • No hiring required
  • Ensures quality control

Is reworking done by hand?

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

Is it expensive to get something reworked?

Reworking is not always expensive. But it can be critical to ensuring a product is saleable in terms of aesthetics and other considerations, or meets legal requirements and regulations.

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

What is the process when getting a package reworked?

  1. Customer request/discussion - Customer discusses with contract packer their requests and specifications, any required samples, expected costs and other issues.
  2. Stock for reworking sent to contract packer - Customer sends their products that require altering to the contract packer. Customer is made aware of successful delivery.
  3. Reworking process - Customer specifications are met to the highest quality during production.
  4. New products delivered - Once the reworking process is complete, the contract packer will ship the products back to the customer.

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

Size and quantity will influence project duration. We rework from a single or part pallet load, to multi-pallet and multi-lorry consignments.

Common ways packaging gets damaged

Packaging and products can get damaged in several ways:

  • Impact and shock - This can be caused by mishandling, products being dropped, collisions during transit, etc.
  • Vibration - Specialist and delicate items can be sensitive to vibration.
  • Moisture - Leaks, spillages, rain and condensation can cause damage to standard packaging. This can be detrimental for electronic products. If there are any risks of moisture, it is worth investing in water-resistant packaging.
  • Temperature/humidity - Extreme hot temperatures can cause packaging and products to become pliable, while lower temperatures can cause objects to become brittle and degrade.
  • Wrong packaging - Sending out products in the wrong packaging can be disastrous. Packaging fragile electronic equipment in cheap cardboard, for example, can result in a lot of problems.

How to avoid product damage with the right packaging

Protecting products can be easily achieved by ensuring the proper packaging material is used. Bubble wrap and durable packaging, for example, can help absorb impact and shock.

If you’re unsure of the best packaging for your product, contact WePack’s friendly and knowledgeable team today.

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Further Information

To find out more about WePack's product reworking service please contact WePack on 0115 852 9000 or get in touch via the form below.