Prime Packaging overcomes operational hurdles with new MIS

Prime Packaging is an award-winning packaging provider, conveniently located just minutes from O’Hare International Airport near Chicago. Founded in 1980, the company initially focused on narrow web-printed roll stock. Now, it works with Fortune 500 companies in the food, beverage, personal care, household and pharmaceutical sectors.

The company operates roll-fed flexo presses that offer up to 11 colors using water-based and UV inks. Kevin Kollman acquired Prime Graphics in February 2010 and formed Prime Packaging. The company produces various labels and flexible packaging, including shrink sleeves, pouches for seasonings and spices and more.

Prime Packaging has been operating for many years but has faced significant operational challenges as it tries to keep pace with the evolving market demands.

Its legacy systems had become outdated and inefficient, leaving the company struggling with manual processes and siloed data. Recognizing the need for a change, Kollman realized the time had come to find a new technology to streamline operations and unlock Prime Packaging’s full potential.

‘We had an older MIS whose supplier had discontinued support some time ago, and the system ran on Windows 7,’ says Kollman. ‘We finally decided it was time to find a better technology.’

“Without real-time data, we were unable to optimize our processes or make informed decisions quickly, which meant we were missing opportunities”

Prime Packaging’s struggles included slow, cumbersome reporting through Crystal Reports and a lack of integration between systems, which created inefficiencies in everything from inventory management to production scheduling.

Kollman adds: ‘We had no inventory system, that was all manual; nor did we have any shop floor data collection. It was time to step up a few levels.’

The company’s reliance on manual processes was a major roadblock, and decision-making was delayed without the ability to access real-time data. Prime Packaging needed to overhaul its systems to continue to grow and improve operational efficiency.

Outdated systems stifling growth

The company’s legacy systems caused inefficiencies at every turn. Daily operations involved manually inputting data into third-party systems like QuickBooks, which consumed significant time and left room for human error.

‘Our estimating system didn’t really work for us. We were using convoluted Excel spreadsheets, and the process wasn’t accurate,’ Kollman recalls. ‘As a result, estimates were slow to go out, frustrating both the team and customers.’

On top of that, Prime Packaging lacked a warehouse management system (WMS), meaning inventory tracking was entirely manual and prone to errors.

‘Our inventory system had been a manual one, so a warehouse management system was definitely on the radar,’ Kollman points out.

This lack of automation and real-time data was causing more delays, impacting the company’s ability to grow.

‘We were really struggling with integrating different systems,’ he adds. ‘Without real-time data, we were unable to optimize our processes or make informed decisions quickly, which meant we were missing opportunities.’

Overhauling systems

To tackle these operational inefficiencies, Prime Packaging turned to HiFlow Solutions, a software provider with a reputation for offering comprehensive and fully customizable systems. Kollman appreciated the flexibility of HiFlow’s offering, which allowed him to configure the system according to his specific needs.

‘I like the fact that the HiFlow system was very comprehensive, yet I could configure just what I needed for my company,’ he says.

The HiFlow system provided Prime Packaging with the tools it needed to streamline operations, improve data accuracy, and integrate the production process. With modules covering inventory management, production planning, and reporting, Prime Packaging eliminated its manual inventory system and gained real-time data to improve its decision‑making.

Kollman explains: ‘With HiFlow, the inventory management and other modules in its WMS offered substantial functionality. And I had access to reports from any of the WMS modules right from HiFlow’s dashboards.’

This shift allowed for better tracking of raw materials, work-in-progress and finished goods, making inventory management much more efficient.

Connecting machines and systems for real-time data

Integrating machines into HiFlow’s system was Prime Packaging’s biggest challenge.

‘It was a bit of a challenge finding the correct hardware to connect our machines to HiFlow’s data collection system,’ Kollman admits. ‘However, with support from HiFlow’s team, the integration was smooth, ensuring that data flowed seamlessly in real-time.’

This integration allowed for continuous operational monitoring and optimization.

‘Through collecting data from machines and production processes, our production process is optimized using the tools from HiFlow’s Production Planning and Production Preparation modules,’ Kollman says.

The result was improved visibility into production status, resource utilization and labor productivity, empowering Prime Packaging to stay on top of every stage of the process.

HiFlow’s integration with QuickBooks also proved to be a big advantage for the company.

‘Integration with QuickBooks was fast and seamless, with bi-directional communication,’ Kollman notes. ‘With this integration, financial data was always up-to-date, making accounting and financial reporting much more efficient.’

Before the upgrade, Prime Packaging’s estimating process relied on outdated Excel spreadsheets, leading to inaccuracies and delays.

Kollman notes: ‘We had been doing estimating with Excel spreadsheets; PSI just was not working. I found HiFlow’s estimating modules easy and fast, and easy to compare estimates to actuals.’

This streamlined the process, making it faster and more accurate, ultimately improving customer service. The new system’s flexibility also allowed for customized reporting.

‘We like the flexibility of the reports we can generate and our ability to access real-time data and information across the entire operation,’ Kollman says. ‘This ability to create tailored reports gave us more control over our operations, allowing us to identify inefficiencies and improve processes across the board.’

Improved customer service

HiFlow’s impact wasn’t just felt internally; it also enhanced Prime Packaging’s customer service.

‘Our customer service now has the ability to immediately access information when a customer calls for a status update,’ Kollman says.

With a centralized database, customer service representatives can easily find job status updates, reducing the time spent looking for information and providing customers with faster responses.

Additionally, HiFlow’s automation features, such as email triggers, have improved customer communication.

‘We can set triggers for automated emails to customers that give them information about production status and shipping,’ Kollman explains. ‘These automated notifications have enhanced the customer experience, giving clients real-time information about their orders and improving satisfaction.’

Supporting smooth transition

Switching from an older legacy system to a modern software technology came with its challenges, especially for a team that had been using the previous system for 15 years.

‘We had been using the older system for 15 years, so there was a lot of change for our employees,’ Kollman says. ‘HiFlow recorded all of our training sessions, and we have them in a library for future reference in case someone needs a refresher, or we are onboarding a new employee.’

“The new system, because it offers visibility, connectivity, and access to real-time data for our reports, definitely makes us more competitive in our market segment”

The in-person support HiFlow’s team provided during key implementation stages also helped Prime Packaging’s employees better understand and appreciate the new system.

‘The HiFlow implementation team was able to take us through our workflow, walk the plant, meet with our team where they work and help with any questions directly at their workstations,’ Kollman says. ‘This personalized approach made the transition smoother and ensured that the team was confident in using the new system.’

One key reason Prime Packaging chose HiFlow over other software developers was the level of support provided by the team.

Kollman recalls: ‘I dealt with the vice president of sales, Jack Lafler, and at every step of the inquiry process. He answered all of my questions and offered as many demos as I needed.’

HiFlow’s willingness to go above and beyond to meet Prime Packaging’s needs was a deciding factor in choosing the system. Kollman also appreciated that HiFlow’s team spoke the same language as his team, which made communication much easier.

‘I was impressed with the fact that everyone on the HiFlow team, from sales to the developers, spoke our language; all of the HiFlow team were familiar with the terminology and processes that I use every day, and we felt quite comfortable that our needs were understood,’ he says.

A stronger, more competitive Prime Packaging

Prime Packaging’s decision to implement HiFlow Solutions has proven to be a turning point for the company. With real-time data, improved reporting, seamless integration and streamlined operations, Prime Packaging has positioned itself for future growth. The company can now make faster decisions, optimize production and offer a higher level of service to its customers.

The successful implementation of HiFlow has made Prime Packaging more agile, data-driven, and competitive in a fast-evolving market.

‘The new system, because it offers visibility, connectivity, and access to real-time data for our reports, definitely makes us more competitive in our market segment,’ Kollman concludes.

Looking ahead, Prime Packaging is well-equipped to handle new challenges and continue growing in the flexible packaging industry. The company is ready to meet the demands of an ever-changing marketplace.