Weyers Cave, VA – Abbott-Action Packaging has significantly improved print quality, operational efficiency, and waste reduction following the integration of A.G. Stacker’s Sample Quality Rejection System with Valco Melton’s PrintChek technology. This cutting-edge solution has transformed quality assurance and production processes, setting a new industry standard.
Addressing Industry Challenges
Before this integration, Abbott-Action’s operators manually monitored print quality, relying on spot inspections that posed risks at high production speeds. With machines running at 15,000 boxes per hour, achieving 100% defect detection and elimination without stopping production was nearly impossible. The manual process also led to customer returns, credits, and rework costs, impacting efficiency and trust. While these challenges were minor, their goal was, and has always been, zero defects.
A.G. G3™ Stacker with SQR — rejected board shown
“This new machine technology represents a major leap forward in our commitment to innovation and efficiency. By integrating cutting-edge automation and smart analytics, we’re not only improving performance and reducing downtime—we’re also setting a new standard for what our industry can achieve.”
–J. Samuel Abbott, CEO, Abbott-Action Packaging
A Transformational Solution
Since integrating A.G. Stacker’s Sample Quality Rejection System and Valco Melton’s PrintChek, Abbott-Action has seen a significant reduction in misprints and waste, while ensuring defective products never make it to final packaging.
- Automated Quality Control: Defects are instantly detected and rejected, eliminating manual intervention.
- Increased Efficiency: Operators can now focus on running machines at peak speeds rather than manually inspecting print quality.
- Improved Waste Reduction: Fewer rejected products mean lower material and labor costs.
- Enhanced Customer Satisfaction: The company is better positioned to deliver flawless products, strengthening client relationships.
“At Valco we embrace challenges as opportunities. We continue to thoughtfully develop our inspection systems to meet and surpass the demands of our customers. The result is a product that not only meets customer expectations but also raises the bar for excellence across the market.”
–Jeff Pollack, National Sales Manager, Valco Melton
PrintChek screen displaying detected errors
PrintChek scanning bar and camera system
Competitive Advantage & Industry Leadership
This integration has positioned Abbott-Action at the forefront of the corrugated packaging industry, delivering the highest print quality at high-speed production. As an early adopter of this technology, Abbott-Action is setting new benchmarks for quality assurance.
Looking Ahead
While the data is still being collected, early results indicate a significant drop in quality issues and returns. Abbott-Action is confident that this technology will continue to drive efficiency, customer retention, and new business opportunities.
About A.G. Stacker
Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions. www.agstacker.com
About Valco Melton
Headquartered in Cincinnati, OH, Valco Melton has been a global leader in adhesive dispensing and vision inspection systems for over 70 years. Serving corrugated manufacturers in 96+ countries, Valco Melton delivers innovative solutions like ClearVision® camera inspection, backed by world-class service and support. www.valcomelton.com
About Abbott-Action Packaging
Founded in 1935 and headquartered in Attleboro, MA, Abbott-Action Packaging is a third-generation, family-owned leader in corrugated packaging and POP display solutions. Built on a legacy of innovation and strategic growth, the company continues to deliver high-quality, customized packaging that helps brands stand out in today’s competitive market. www.abbottaction.com