Balancing Flexibility and Throughput in High-SKU Plastic Packaging Printing
MasterCut Tool runs more than 20,000 active SKUs, each in its own plastic case, and no two carry the same artwork.
Case Studies
Real customer applications. Real production cells.
Every EPS line is custom-engineered around the part, the substrate, and the throughput. These are the systems we shipped — what they replaced, what they cost, what they deliver.
Hands-Off From Stack to SKU: Robot-Loaded Single-Pass Decoration
A six-axis robot feeds the line from a bare stack and an automated off-load sorts finished parts by SKU — so on a high-mix promotional floor, nobody touches a part between the pallet and the packing bench.
Cold-Foil Award Ribbons — No Dies, No Heat, No Typesetting
An awards and recognition ribbon converter replaces hot-foil stamping with digital cold foil — 14.5 linear inches per second, 5,760 finished pieces an hour, and lead times that fell from two days to two hours.
Promotional Products
Photographic Color, Printed Direct Onto Tall Rigid Goods
A promotional-products decorator brings full-color, photo-quality decoration in-house — printing directly onto rigid objects up to 19 inches tall, with no screens, no transfers, and roughly six cents of ink per image.
Promotional Products
One-Off Personalization at Production Speed: Decorating Custom Toothbrushes
A promotional-products decorator turns individually customized toothbrushes into a repeatable production line — custom handling, instant UV cure, and true variable-data printing in a single inline pass.
Promotional Products
Any Part, Any Color, No Setup: Flexible Inkjet Decoration for Promotional Goods
One flatbed multi-pass inkjet decorates a constantly changing mix of promotional parts — zero plate setup, custom jigs for fast loading, and extended-gamut color that hits corporate brand standards on demand.
The New, Improved XD-360 — Bowl-Fed, Print, Cure, Inspect, Discharge
A high-volume manufacturer of plastic cylindrical components — sprinkler bodies, dispensing closures, fittings, and similar hardware — replaces a multi-step decoration line with a single XD-360 cell that bowl-feeds, prints, cures, and inspects every part before discharge.
Photographic Wood-Grain Printing on Plastic Trim — Direct-to-Shape, Operator-Free
Three printhead sets, top and two sides, single straight-through pass. Photographic wood-grain locked to physical reference panels. Automated load to automated unload.
Why a Soccer Ball Is a Pad-Print Problem — and Stays One
A textbook stable-graphic, complex-3D application. One cliché, one pad, every ball — at production volume across multiple substrate colors.
Decorating Plastic Cups at 1,200 Parts an Hour on the XD-360
Cylindrical-by-design single-pass cell. Five color stations baseline, scales to eight in the same chassis. Print and cure synchronized — no offline drying, no inter-color WIP.
Photographic-Quality Clamshell Decoration — W+CMYKOGV with Inline Inspection at Production Speed
Corona-treat. White underprint. 8-color expanded gamut on top. Every clamshell vision-inspected — only acceptable prints leave the line.
Decorating a Hardhat in One Robotic Cycle — Crown, Brim, and Sides
Load once. Robotic spindle owns the geometry. Multi-color pad + inline UV-LED cure — finished hat off the spindle in one cycle.
Fourteen Colors on a Catheter, with One Operator at the HMI
Fourteen pad-print stations consolidated onto one chassis. One technician at the HMI. Labor collapse engineered into the line.
High-Volume Syringe Decoration — Up to 10,000 Pieces an Hour, Clean-Room Ready
Bulk-in to decorated-out. 360° graduations in one index. Zero operator hands on parts.
Personalized Hard Hats — All Four Sides in Under 60 Seconds
Front, back, and both sides decorated in one sub-60-second cycle. Per-helmet variable data without slowing the line.
Floss Container Decoration on the XD-070 — Corona Pretreatment Plus Zero-Changeover Single-Pass Inkjet
Every container corona-treated. Every SKU change a software swap. No plates, no operator changeover.
1,200 Golf Balls an Hour, Each One Different: Single-Pass Inkjet on Curved Surfaces
A multi-station pad cell replaced by one XD-360 line — variable-data ball decoration at production speed.
Printing the Unprintable — Multi-Color Decoration on Oscillating Multi-Tool Blades
Label + pad-print workflow collapsed to one single-pass cell. Zero human touches between load and pack.
The EPS ClosurePrint System — Production-Speed Pharmaceutical Closure Decoration
Bulk caps in, printed inspected caps out. No operator handling. Single-pass print + integrated cure.
Single-Pass Inkjet Plus Robotic Pick-and-Place for Reciprocating Blades
No operator handling. Single-pass print + integrated LED-UV cure in one continuous cell.
Short-Run Food & Beverage Packaging
Short-Run Lid Decoration at Production Speed — Without Changeover Costs
Zero changeover. Multiple SKU's every shift. Offset-quality print at single-pass throughput.