In November 2022, a client brought Bray Solutions the largest rework task in our history: relabelling over 8 million packs of seeds and nuts within a three-month window. Here is how we did it. 

In early November 2022, a client contacted Bray Solutions with a task that was unlike anything we had been asked to do before. They needed to relabel over 8 million individual packs of seeds and nuts, across multiple product types and label specifications, within a three-month window. The client had the stock ready. They did not have the facilities, the label supply infrastructure, or the operational capacity to carry out a project of this scale themselves. 

This was the largest rework task ever brought to Bray Solutions. The response was straightforward: we ran the numbers, confirmed we could meet the timeline, and committed to the project. What followed over the three months it took to complete was a demonstration of what a specialist contract packing operation with the right equipment, the right supplier relationships, and the right operational processes can deliver when it is put to the test. 

This article details how we approached the project from initial brief to final completion, what the operational challenges were, how we resolved them, and what the experience demonstrated about the scale of rework and relabelling projects that Bray Solutions can absorb. 

Key Takeaways 

• The seeds and nuts relabelling project, completed in November 2022 to early 2023, involved over 8 million individual product packs and was the largest rework task ever undertaken by Bray Solutions 

• The project required relabelling across multiple product types with different pack formats and label specifications, adding coordination complexity beyond a single straightforward relabelling operation 

• Being food products, the best-before date on each pack was a primary consideration in the project timeline: completing the work within three months ensured the maximum possible remaining shelf life for the relabelled stock 

• Label sourcing was a critical path item: with 8 million packs to process across multiple label specifications, establishing reliable supply from trusted suppliers before stock arrived was essential to maintaining throughput 

• Quality control was embedded at every stage of the process, including regular sampling, supervisor sign-off, and final review, to ensure label application accuracy across the full volume without creating a secondary rework requirement 

• The project was completed on time and to specification, demonstrating that Bray Solutions’ contract packing capability can absorb large-scale rework without disrupting ongoing ecommerce fulfilment operations for other clients 

The Brief: 8 Million Packs, Three Months, and a Best-Before Date That Would Not Wait 

The client’s requirement was precise and time-bound. They had a large volume of seed and nut products, across multiple product types, that required new labels applied to every individual pack. Completing the relabelling operation as quickly as possible within the three-month window was not just about meeting the client’s deadline. It was about preserving as much remaining shelf life on the stock as the timeline allowed. 

Starting Before the Stock Arrived: Why Label Sourcing Was the Critical Path Item 

With 8 million packs to process across multiple product types with different label specifications, label supply was the element with the longest lead time and the highest risk of becoming a bottleneck. Bray Solutions has established relationships with reliable label suppliers who can respond quickly to large-volume requirements. Label specifications were shared with our preferred suppliers as soon as the brief was confirmed, and we worked with them to confirm availability and production timelines before the first pallet of stock arrived at our facility. 

Coordinating Inbound Stock to Match Throughput Capacity 

With label supply confirmed, the next operational challenge was managing the arrival of 8 million packs in a way that kept the relabelling operation running efficiently without overwhelming the warehouse. Inbound deliveries were scheduled to arrive at a pace that kept the operation consistently supplied without building up a significant queue of unprocessed stock. The rhythm of inbound and processing needed to be sustainable over three months, not just achievable in the first week. 

Quality Control Across 8 Million Individual Packs 

With 8 million individual applications to make, a small error rate in percentage terms can translate into a very large number of incorrectly labelled packs. The approach combined regular sampling with supervisor sign-off at defined stages. Rather than sampling only at the end of the operation, sampling was conducted regularly throughout the relabelling run so any deviation from specification was identified before it had propagated through a significant additional volume of stock. A final review of a sample of the completed stock before release confirmed the overall quality of the project met the client’s specification. 

The Outcome: Completed on Time, on Specification, and With Both Teams Satisfied 

The project was completed within the agreed three-month window. All 8 million packs of seeds and nuts were relabelled to specification, quality checked, and either reintegrated into our warehousing and storage system for ongoing fulfilment or made ready for distribution. 

Both the client and the Bray Solutions team were extremely satisfied with the outcome. The project demonstrated that the contract packing and rework capability at Bray Solutions can absorb projects at a scale that would be genuinely challenging for most 3PL providers, while maintaining quality standards alongside the ongoing fulfilment operations of all other clients. 

If your business has a rework, relabelling, or repackaging requirement that feels too large or too complex to tackle in-house, that is exactly the kind of challenge we are built to handle. The operational disciplines that made the seeds and nuts project successful, the upfront label sourcing, the coordinated inbound scheduling, the embedded quality control, and the experienced team managing the throughput, are the same disciplines that make every contract packing engagement at Bray Solutions work reliably, at whatever scale the project requires. 

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Frequently Asked Questions 

Q: What made the seeds and nuts relabelling project particularly complex? 

A: The combination of scale, time constraint, and product diversity. With over 8 million individual packs across multiple product types with different label specifications, the project required simultaneous management of label sourcing for multiple formats, coordinated inbound scheduling to match throughput capacity, and quality control processes robust enough to catch errors within a small volume of output. 

Q: Why was the best-before date a primary consideration in the project timeline? 

A: Because the products were food items, every day the stock sat unprocessed reduced the remaining shelf life available to the retailer or consumer. Completing the relabelling within three months was about preserving as much remaining shelf life on the stock as the timeline allowed, not just meeting a deadline. 

Q: How did Bray Solutions manage label supply for 8 million packs across multiple specifications? 

A: By securing label supply from established supplier relationships before the first pallet of stock arrived. Label specifications were confirmed with suppliers at the outset and stock confirmed before the operation began, eliminating the risk of a supply interruption partway through the project. 

Q: How was quality maintained across 8 million individual label applications? 

A: Through regular sampling throughout the operation rather than only at the end, supervisor sign-off at defined throughput milestones, and a final review of completed stock before release. This approach means any quality deviation would be identified within a small volume of output and corrected before it propagated significantly. 

Q: Can Bray Solutions handle large rework projects without affecting other clients’ fulfilment operations? 

A: Yes. Bray Solutions managed this project of 8 million units alongside the ongoing fulfilment operations of all other clients without disruption. Dedicated operatives, careful inbound scheduling, and clear separation between the rework project and standard fulfilment operations are the disciplines that make this possible.