From Concept to Commissioning: Inside Impresstik’s Custom Engineering Process
Every production line is different. Every container, product, speed target, and compliance requirement brings its own set of challenges. That’s why truly reliable labelling performance doesn’t come from off-the-shelf machinery — it comes from engineering.
At Impresstik, custom engineering isn’t an add-on. It’s what we’re known for. For more than 45 years, our team has designed and built custom labelling systems that meet the specific needs of Australian and global manufacturers. Whether it’s adapting to complex line layouts, achieving high-speed accuracy, managing temperature or moisture challenges, or integrating labelling with print-and-verify systems, our process is designed to produce one outcome: a labelling solution that fits perfectly into your production environment and delivers long-term efficiency.
This article walks through each stage of our engineering process — from the first conversation to final commissioning — and explains how we turn complex requirements into reliable, high-performance machinery.
Why custom engineering matters
Before exploring the process itself, it’s worth understanding why custom solutions are often the superior choice for production lines.
Most generic labelling systems are made to operate across a broad range of applications. While they work adequately for standard packaging, they struggle when manufacturers need:
unique container handling
integration with upstream or downstream equipment
higher speed or greater throughput
non-standard label shapes or sizes
specific compliance requirements (TGA, FSANZ, export, etc.)
unique environmental considerations
tailored operator controls
space-limited layouts
A custom-engineered system is designed to solve these challenges rather than work around them. The result is better accuracy, uptime, consistency, and long-term cost control.
This brings us to the Impresstik process.
Step 1 — Technical consultation
The starting point is always technical understanding.
We meet with your team — production managers, engineers, line operators, or decision-makers — to map out how your products are currently being labelled, where the challenges lie, and where improvements are possible.
During consultation, we gather:
container types and materials
label formats
production speed targets
compliance requirements
pain points (misalignment, slippage, downtime, etc.)
expected growth or future changes
available floor space
integration requirements
operator workflow and ergonomics
This stage ensures that the engineering solution is grounded in your real-world conditions, not theoretical assumptions.
The goal is simple: understand the production environment from end to end.
Step 2 — Design and 3D modelling
Once the requirements are clear, our engineering team begins designing your labelling system.
This stage includes:
3D modelling of the full equipment layout
mounting frameworks
product handling and stabilisation systems
label feed and application assemblies
control interfaces and electronics
integration points for printing or vision systems
The 3D model allows you to see exactly how the system will operate in your environment — including how products enter, how labels are applied, how quality checks occur, and how containers exit downstream.
This reduces risk, eliminates surprises, and ensures every component is in the right place before manufacturing begins.
The benefits of detailed design
Faster manufacturing
Fewer onsite adjustments
Optimised container handling
Improved ease of maintenance
Precise integration with your existing equipment
In short, design is where accuracy is engineered.
Step 3 — Custom manufacturing
Once the model is approved, we move into production at our Australian manufacturing facility.
This is a major advantage over imported machinery:
we control the materials, tolerances, assembly process, and quality checks.
There’s no compromise and no uncertainty in the production process.
Our manufacturing includes:
cutting, machining, and fabricating components
building product handling systems
assembling applicators and servo-driven modules
wiring and control system installation
building mounting structures and guarding
We only use materials and components suitable for Australian conditions — reliability is built into every decision.
Step 4 — In-house testing and validation
Before your system ever reaches your facility, we undertake comprehensive in-house testing.
We run through:
speed tests
endurance operation
label accuracy validation
container handling consistency
integration checks for print-and-apply systems
safety and compliance checks
Testing ensures that once your system arrives onsite, installation and commissioning are fast, precise, and predictable.
Why in-house testing matters
It eliminates:
unexpected delays
calibration issues
onsite downtime
misalignment or adhesion issues
You receive a system that’s ready for production — not one that still needs fine-tuning.
Step 5 — Installation and commissioning
Once the machine is fully validated, our team installs the system on your site.
Commissioning includes:
final alignment and calibration
integration with conveyors or production equipment
validation of label application at target speeds
operator workflow optimisation
training for your staff
safety checks and sign-off
Our goal is to ensure your team is confident, your line is performing at full speed, and your new system is delivering value from day one.
Step 6 — Ongoing support and lifetime partnership
A custom labelling machine isn’t a one-off purchase — it’s a long-term tool for efficiency.
That’s why ongoing support is a core part of what we provide.
Our support includes:
maintenance planning
remote troubleshooting
parts availability
optimisation for future product changes
support when production volumes grow
guidance on integrating new technology
Whether you upgrade containers, change label formats, or increase speed targets, we ensure your system evolves with your business.
When you choose custom engineering, you’re choosing a system that grows with you — not a machine that becomes outdated.
Why Impresstik’s process works
Our engineering process is built around the realities of modern manufacturing:
need for reliability
demand for higher throughput
strict compliance requirements
growing product variety
increased automation
reduced operator intervention
integration with smart systems
Because we design, build, and support everything in-house, you get consistency from start to finish.
There are no gaps, no miscommunications, and no reliance on overseas scheduling.
Everything sits under one roof — engineering, manufacturing, testing, installation, and support.
This is how we deliver systems that perform day after day, shift after shift.
Built for Australian and global manufacturing
Our systems are used in:
food and beverage facilities
nutraceutical and wellness manufacturers
pharmaceutical and healthcare operations
personal care and cosmetic production
industrial products
export packaging
contract manufacturers
Each of these sectors brings unique challenges — and our process ensures every solution matches those challenges precisely.
From small vials and glass bottles to complex round, oval, or tapered containers, our systems are built to handle the real-world demands of each industry.
Your production line deserves a purpose-built solution
If your organisation is experiencing:
misaligned labels
shrinking operating windows
increased product variation
bottlenecks at the labelling station
integration challenges
rising labour costs
or inconsistent application at higher speeds
…a custom-engineered system will deliver immediate improvements and long-term returns.
Speak with our engineering team
If you want a system designed specifically for your production line, our team is ready to help.
Speak with our engineering team to explore how Impresstik can tailor a solution for your needs.
Labelling Machines
https://www.impresstik.com/labelling-machines
Contact
https://www.impresstik.com/contact
