Case Study
National Food Service Distributor Saves Thousands with OMNI Systems
Client Overview
A leading national distributor of food products and services, this company supplies:
Food & beverages
Menu planning & inventory programs
Software solutions
Other essential products & services
Serving restaurants, hospitals, hotels, and various businesses, the company operates 32 locations nationwide, each requiring a reliable, cost-effective labeling solution to keep operations running smoothly.
Key Savings with OMNI Systems:
💰 $1,000 saved per month on labeling costs
⏳ 5,884 hours of printhead lifespan (a 27x increase!)
📏 449,424 inches of labels produced without printhead failure
The Challenge
High-Volume Labeling with Performance Issues
Labels are critical to the company's operations, used for:
Warehouse inventory tracking
Order picking & pallet stacking
Shipping & delivery verification
Each item in the warehouse has a “pick sticker”, and each storage rack has a “rack sticker” listing all items stored there. Warehouse workers, known as “pickers”, retrieve products from racks, scan them for order fulfillment, and prepare pallets for shipping. Delivery drivers then scan pick stickers upon drop-off to verify correct shipments.
Pain Points with Previous Labels:
🚫 Poor label quality – Labels frequently tore, faded, or failed to scan
🚫 Printhead failure – Labels caused excessive wear, leading to frequent, costly printhead replacements
🚫 Adhesive issues – Labels fell off racks and pallets, disrupting operations
🚫 Inconsistent supply chain – The company needed a provider who could serve all 32 locations with uniform labeling solutions
With high-label demand and frequent issues, the company was losing money on reprints, equipment failures, and operational inefficiencies. Their business systems administrator knew they needed a better, more cost-effective labeling partner.
The OMNI Solution
A Custom-Engineered Labeling Program
When the company approached OMNI Systems, we collaborated directly with their business systems administrator to test, refine, and implement a tailored solution.
Key Improvements:
- Switching to High-Performance White Labels
The company previously used color-coded labels for sorting and routing, but:
❌ Colored labels were expensive and required costly materials
❌ Printheads wore out faster due to additional pigment layers
❌ Scanning issues reduced efficiency
OMNI recommended all-white labels, which provided:
Lower costs per label
Increased printhead lifespan
Faster, more efficient printing without quality loss
- Upgrading to Top-Coated Labels for Durability
OMNI introduced top-coated direct thermal labels, specifically designed for food service applications. These labels:
Print faster and clearer than previous labels
Reduce friction & wear on printheads, extending their life
Enable flawless barcode scanning for inventory accuracy
- Implementing a Printhead Cleaning Protocol
Since printheads are a major expense, OMNI worked with the client to develop a cleaning regimen to extend their lifespan. By increasing cleaning frequency and using 99.5% alcohol wipes, the company saw a dramatic increase in printhead longevity.
Customer Testimonial:
"Any label company can provide labels. But if a problem arises, who responds, and how quickly? With OMNI, the response is immediate. Their team comes on-site, identifies the issue, and fixes it. Their service is impeccable!"
— Business Systems Administrator
Results
Massive Cost Savings & Efficiency Gains
With OMNI’s solution in place, the company saw immediate, measurable improvements:
📈 Improved Operations & Reliability:
No more label failures—stickers stay in place and scan perfectly
Faster, more efficient printing across all 32 locations
Seamless nationwide label supply, ensuring consistency across all facilities
💰Cost Savings
$1,000 saved per month on labeling expenses
Reduced printhead replacements, cutting equipment costs
⏳ Extended Printhead Lifespan:
Before: Printheads lasted 212 hours, printing 79,524 inches of labels
Now: Printheads last 5,884 hours, producing 449,424 inches of labels—a 27x increase!
Is Your Business Ready for a Smarter Labeling Solution?
OMNI Systems delivers high-quality labels at the lowest total cost, helping businesses like yours save money, reduce downtime, and streamline operations.
Contact OMNI Systems today to see how we can optimize your labeling process!