A-Z Color achieves zero-defect pharma label production

Polish printer, A-Z Color, began operations in Ostrołęka, Poland, in 1992, from an area measuring 20sqm. Over its 30-year history, it has evolved from a small plant producing mainly simple, single-color labels into a modern flexographic printing house, well-equipped and continually expanding its offerings.

A period of rapid development for A-Z Color began in the late 1990s. The world-class machinery that was purchased then transformed it into a company with a diversified production profile. The following years of dynamic development led to the construction in 2006 of a 3,850sqm, modern production plant and further expansion of the machinery park.

“In an industry where a single missing point can mean the difference between success and failure, EyeC is our life insurance”

Today, with over 90 employees, the family-owned company manufactures high-quality self-adhesive labels, shrink sleeves and flexible packaging for customers in the cosmetics, food and pharmaceutical industries throughout Europe. Its mission: uncompromising precision in every print, especially in regulated markets. The label manufacturer confirms this promise of quality with ISO 9001:2015, BRCGS Packaging Materials and FSC certifications, as well as DPG qualification for the German market.

A-Z Color provides comprehensive printing services from design to delivery of ready-made labels. To meet the ordering parties’ expectations to the best of its ability, the printing house operates under an integrated management system that enables complete control of all production processes. A customer service department was established within the printing house to provide advice and professional assistance throughout production preparation.

Pharmaceutical quality

In the pharmaceutical industry, precision is paramount. An incorrectly placed decimal point in dosage instructions, a slight change in batch number or a subtle color change on a warning label can have serious consequences.

‘Our priority has always been to deliver products that meet our customers’ high expectations,’ explains Katarzyna Zecer‑Gołaszewska, partner at A-Z Color. ‘However, in a dynamic market that does not forgive mistakes, ensuring absolute reliability at every stage of production was a real challenge.’

For a company serving customers across Europe in highly regulated industries, maintaining strict quality standards while meeting production deadlines and efficiency targets has been an ongoing operational challenge.

A-Z Color faced the challenge of finding a future-proof, automated technology that would combine 100 percent reliability with maximum production speed. The company needed a system that could meet the exacting standards of pharmaceutical manufacturing while integrating seamlessly into existing production workflows without compromising efficiency.

Evaluation process

A few years ago, A-Z Color implemented its first automated print inspection systems and evaluated their performance over the long term. The selection criteria were simple and included ultra-precise detection, stable 24/7 performance, easy integration, user-friendly design and reliable operation.

‘When selecting the right product, it is not only the technology and price that matter to us, but also the quality of cooperation,’ emphasizes Zecer-Gołaszewska. ‘We need partners who understand our requirements, share our quality standards and provide us with reliable support in our daily production.’

The evaluation process accounted for the specific demands of pharmaceutical manufacturing, where GMP guidelines set rigorous standards for quality control and documentation. An evaluation of various quality control systems, taking into account pharmaceutical requirements and GMP guidelines, enabled the company to make a clear decision. While competing systems failed in areas critical to the pharmaceutical industry, EyeC systems reliably and consistently detected even the smallest deviations.

This thorough evaluation process demonstrated A-Z Color’s commitment to making strategic technology investments based on real-world performance rather than specifications alone. The company’s approach of testing systems in actual production conditions over an extended period provided invaluable insight into how different technologies would perform.

Dual-system approach

The EyeC Proofiler 600 DT off-line scanner system was used to check the print pattern, while EyeC ProofRunner Web in-line systems were used for 100 percent inspection on the label printing line. This combination of off-line verification and in-line inspection created a comprehensive quality control framework.

The EyeC Proofiler combines intelligent software with a high‑resolution flatbed scanner and enables objective, repeatable quality control of text, colors, graphics, 1D and 2D codes and Braille. It compares printed products against approved PDF templates to verify print quality and content accuracy. This off-line verification step ensures that approved templates meet all specifications before production begins, establishing a verified reference point for in-line inspection.

Using this approach, EyeC ProofRunner Web cameras capture every label during printing. Each item is thoroughly checked for accuracy in color, registration and positioning, and then automatically verified. The system detects and flags errors in real time, so that only error-free products are processed further.

All EyeC systems are equipped with pixel-accurate comparison algorithms that detect deviations of 0.1 millimeters, enable real-time analysis at full production speed and automatically compensate for differences in materials and prints. This level of precision is essential for pharmaceutical applications.

Intelligent contrast analysis also prevents false alarms, a critical feature that helps maintain production efficiency by ensuring operators are alerted only to genuine quality deviations, not to acceptable material variations. If deviations are detected, the system immediately notifies production, precisely locates the deviation and allows operators to make targeted corrections.

By combining off-line and in-line systems, A-Z Color fully digitized its quality control process.

Rapid implementation

After two weeks of technical preparation, including analysis of production lines, infrastructure upgrades and definition of real-world test cases, three ProofRunner Web systems were installed, qualified and tested in a single day.

This efficient installation process reflected both the preparatory work undertaken by A-Z Color and the support provided by EyeC. After operator training, the systems were immediately put into production mode. The installation complied with pharmaceutical standards and included approved documentation (IQ/OQ) and training certificates for all operators.

The installation qualification and operational qualification documentation are essential for pharmaceutical manufacturing, providing the audit trail required by regulatory authorities. Training certificates for all operators ensure that quality control is maintained across all shifts and that systems are operated consistently in accordance with established protocols.

Proven partnership

The collaboration with EyeC was a decisive breakthrough for A-Z Color in label production. In several years and thousands of production orders, only one defective printing template was produced. Following a joint analysis with the manufacturer, insufficient color contrast was identified as the cause. The system parameters were adjusted, and a preventive action protocol was implemented. Since then, the error rate has been zero.

This single incident, rather than representing a system failure, demonstrated the value of the partnership approach. The collaborative problem-solving process identified the root cause, implemented corrective measures and established preventive protocols to ensure the issue would not recur.

This has fundamentally changed quality assurance from random sampling to 100 percent automated inspection on the production line. The most significant advantage: deviations immediately lead to production stoppages, are documented and enable targeted corrections – fully GMP-compliant and audit-proof.

For customers, especially in the pharmaceutical industry, this means no product recalls, complete documentation, audit security and predictable delivery dates. The elimination of product recalls alone represents significant value, avoiding not only the direct costs of recalls but also the reputational damage and regulatory scrutiny that accompany quality failures in pharmaceutical supply chains.

At the same time, waste and reprints have been significantly reduced, resulting in real resource savings and higher production efficiency. This dual benefit of improved quality and reduced waste demonstrates how advanced quality control technology can deliver both compliance and operational advantages.

“When selecting the right product, it is not only the technology and price that matter to us, but also the quality of cooperation”

The investment has also paid off in business terms: A-Z Color has transformed itself from a standard supplier to a preferred supplier for leading pharmaceutical companies. Top audit ratings, extended framework agreements, a growing number of orders, active recommendations and a reduced number of incoming inspections are proof of this increased trust.

‘In an industry where a single missing point can mean the difference between success and failure, EyeC is our life insurance,’ emphasizes Zecer-Gołaszewska.

Company-wide adoption

What began in 2019 as a targeted application in pharmaceutical labels has become a company-wide standard. ‘Over time, we realized that EyeC technology also offers us enormous benefits in other areas,’ adds Zecer-Gołaszewska.

Today, in addition to the EyeC Proofiler, five EyeC ProofRunner systems are integral to production, operating virtually around the clock. The most recent installation took place in 2025. In accordance with internal standards, the systems must always be running when the printing machines are in operation.

This expansion from pharmaceutical applications to company-wide adoption reflects the recognition that quality control benefits extend across all market segments. Monitored and controlled by printing house employees, shift managers and technologists, the systems check the entire printing process during all production shifts, ensuring consistent quality regardless of when production occurs or which crew is operating the equipment.

Strategic quality vision

With the implementation of EyeC systems, A-Z Color has set a new quality standard in label printing that guarantees error-free results. Building on its successes to date, the company is now working to further develop predictive quality control through data-driven analysis and continuous process improvement. The partnership with EyeC is an indispensable foundation for these activities, providing both the technology platform and the collaborative relationship necessary to advance quality control capabilities.

‘Based on our consistently positive experience, we have no hesitation in recommending EyeC as a proven and reliable partner,’ concludes Katarzyna Zecer-Gołaszewska.

Click here to learn more about A-Z Color.