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RELY · Case Study · Variety-pack co-packingNO. 10

VARIETY-PACK CO-PACKING · BEVERAGE BRAND

Your launch date is set. Your packaging line is not.

For a warehouse-club beverage launch, RELY stood up an 18-can, three-flavor variety-pack program from already-finished, sealed cans: receiving, date control, pack mix, palletizing and storage.

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Front page of the Case Study No. 10 PDFView the original PDF
  • 42 daysFirst meeting to first full truckloadMar 6 to Apr 17, 2026
  • 3Full truckloads shipped April 17Ahead of the April 20 launch target
  • 30,000+18-can variety packs540,000+ cans packed, March to September 2026
  • 0Customer-reported pack-mix errorsAcross 30,000+ variety packs

More than packout. A coordinated launch program.

A beverage brand had a warehouse-club launch approaching and needed outside capacity to stand up a new 18-can, three-flavor variety pack. Finished, sealed cans came in. Retail-ready variety packs went out. RELY did not formulate, fill or process the beverage.

LAUNCH TIMELINE, 2026 · LAUNCH TARGET APRIL 20

  1. MAR 6

    First meeting. Scope established

  2. MAR 19

    Quote accepted, PO issued

  3. APR 6

    Production began

  4. APR 17

    Three full truckloads shipped

WHAT RELY OWNED

  • A · Receive and segregate

    Single-flavor product arrived from two origins. RELY staged it by flavor and expiration date so every build drew from the right stock.

    Launch risk handled: wrong stock in, wrong pack out.

  • B · Preserve date profiles

    Separate builds required different expiration-date profiles. RELY segregated inventory by date and held the required profile through packout.

    Launch risk handled: date-sensitive product mixed across builds.

  • C · Control the three-flavor mix

    Six cans of each flavor per carton, packed to the supplied dieline and brand specification, closed and palletized to the supplied pattern.

    Zero customer-reported pack-mix errors across 30,000+ packs.

  • D · Ramp, store and release

    Two shifts, ramped from 4 to 24 associates over two weeks, peak week of 9,453 packs. Finished goods stored at RELY and released on demand.

    Launch risk handled: product ready, but nowhere to put it.

Planning the next run. RELY also evaluated automation options for future runs.

THE PACK

One 18-can carton: flavor A x 6, flavor B x 6, flavor C x 6.

SOURCE: RELY INTERNAL PROGRAM RECORDS. CUSTOMER NOT NAMED. RESULTS REFLECT THIS PROGRAM ONLY AND ARE NOT A STANDARD LEAD-TIME OR CAPACITY COMMITMENT.

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