CASE STUDIES
Koopress
Increases efficiency, simplifies and
automates workflows
The Query
Koopress modernized management systems to get competitive edge.
Koopress, a leading packaging and labeling producer founded in 1991, supplies folding carton packaging and labels to a global customer base, including major brands such as Colgate, RedBull, Toblerone, and Milka. As one of the largest folding carton producers in Poland, Koopress’s daily production exceeds a million products. Facing rapid market growth and increasing pressure from competitors, Koopress’s leadership recognized the need to expand and modernize their operations. Upgrading their ERP system became a crucial step in this strategy, aiming to integrate and streamline their processes, enhance production capabilities, and maintain their competitive edge in the industry.

PRODUCTS
Folding carton, sleeves, trays, barrier coatings
MACHINES
4 x Offset printing with coating
1 x Laminating
1 x Hotstamping and Embossing
5 x Die cutting
5 x Gluing
COMPANY size:
80 + employees
Location:
Warsaw, Poland
The challenge
Manual processes with no real-time data was stifling growth and innovation.
With a daily production capacity for more than a million packaging items, Koopress is a complex and sophisticated operation. Before implementing HiFlow’s ERP system, Koopress experienced significant challenges with growth and innovation using manual processes, labor intensive using Excel spreadsheets for data collection and monitoring processes using email. Communication between departments was challenging and time-consuming manual updates and checks were required to keep records current, diverting resources from more productive activities.
Manual data entry into spreadsheets is susceptible to human error, which can result in inaccurate data that affects the entire production process. These tools do not provide real-time updates, which led to delays in decision-making and response to changes in production needs. And, as Koopress grew, the volume of data and complexity of processes often outgrow the capabilities of spreadsheets and email, making them inefficient for larger scale operations.
The management at Koopress decided to expand and modernize operation by introducing product and process improvements to achieve greater efficiency and switching to an integrated ERP system can address these issues by automating processes, enhancing data accuracy, and improving operational efficiency, and importantly, supporting more dynamic and scalable operations.
“The HiFlow system has simplified the process of tracking products from production using barcode readers. This ensures their full traceability and eliminates manual document entry, which can generate costly mistakes.”
The solution
Koopress sees impressive gains in speed of workflows in estimating, production, warehouse.
Having evaluated seven MIS companies. Koopress chose HiFlow’s software management system to meet its growing needs and gain an edge in the market.
After implementing HiFlow, Koopress noticed significant time savings during machine start up and changeovers. The system also improved efficiency for equipment and operators. Managers can check on jobs at any point in the production process through HiFlow’s customizable dashboards and are able to identify any production bottlenecks in real time. KPIs can be tracked for each job, enabling reporting that is accurate and timely.
Response time for estimates has improved thorugh the tools that HiFlow provides to estimators. The time saved has led to faster conversions from quotes to signed orders.
All employees are functioning more effectively, from sales reps and technologists, to graphic designers and quality control. HiFlow has standardized the flow of job tickets and
communications procedures on all jobs increasing efficiency throughout the company. Effective data collection is improving decision making in all key areas. Report generation provides real time oversight into every department, and the system precisely tracks all planned and actual costs. Managers have accurate, in-depth and timely information for strategic decision making.
Time savings have increased significantly during press start-up and changeover; quicker response times for estimates means orders are signed quickly; job tracking in done in real time; and production bottlenecks are quickly identified and dealt with.
HiFlow centralizes data from various departments into a single, integrated database. This eliminates the need for manual data entry across multiple systems, which is a common source of errors. With real-time data synchronization, employees access accurate and up-to-date information, significantly reducing discrepancies and mistakes. ROI for Koopress has quickly improved.
The HiFlow Warehouse Management System handles timely delivery of raw production materials and reduces inventory costs. The system provides real-time updates and manages inventory requirement down to the minute, so the purchasing department can make accurate decisions that save money. “The HiFlow system has simplified the process of tracking products from production using barcode readers”, said Romuald Kowalczyk, head of implementation at Koopress. “This ensures their full traceability and eliminates manual document entry, which can generate costly mistakes.”
The company has regained its spot as the leading packaging provider, met its growth targets and modernized operational performance.
“The HiFlow system has simplified the process of tracking products from production using barcode readers. This ensures their full traceability and eliminates manual document entry, which can generate costly mistakes.”
Takeaways
Easy, short implementation
Koopress stakeholders were very pleased about the 5-month implementation process. The shortened timeframe is the result of HiFlow’s unique mplementation strategy which customizes the software package to meet the exact needs of the packaging company. The development and implementation team engages company staff early in the process, makes site visits, maintains timelines, and provides very regular communication with key members of the Koopress staff. HiFlow guarantees that the system will be ready for all future challenges.
Intuitive interface creates transparency
HiFlow’s interface is familiar with most operators, shop floor workers and business managers: it’s Microsoft based, allowing easy navigation. The standard ribbon-type GUI allows estimators, job planners, customer service and office personnel easy access. For Koopress, this meant that communication between departments has improved and there is a standardized flow of job tickets and communication procedures for every job. Employees can perform their tasks anywhere and at any time on mobile or tablet devices, allowing greater freedom and flexibility.
In depth data collection; data visualized
HiFlow’s data collection capabilities facilitates decision making in all key areas of the company’s operations—from production to human resources. HiFlow improves daily operations through connecting all departments in a central database. All aspects of a job are accessible from throughout the organization in real time. From the visually enhanced business intelligence and reporting to visual workflows, to shop floor monitors with real time updates, HiFlow provides Koopress with information about how the entire plant is functioning.
The Benefits of Partnering
with HiFlow Solutions

We implement – fast. The HiFlow system combines MIS and MES software with easy ERP integration.

We fill your ERP gaps. By optimizing ERP systems with MIS and MES features required for packaging and label printing.

We create automated environments. With seamless connections from order intake to shipping and invoicing.

We feed you data. With insights from real time, critical information from your production shop floor, personnel, and equipment.

We let you see. From smart scheduling to nested layouts to workflow diagrams, instantly see where you stand within the job.