As one of the largest privately held label manufacturers in the United States, Repacorp has built its reputation on being responsive, flexible, and remarkably versatile. With a wide range of capabilities spanning from stock labels to shrink sleeves, RFID, and flexible packaging, the company supports a broad and fast-moving reseller market that expects both speed and scale.
So when it came time to evolve their digital printing footprint, Repacorp was looking for more than just another piece of equipment. They were looking for a long-term partner—and a press that could handle the increasing demands of multi-SKU production without sacrificing efficiency or quality while opening capacity and expanding throughput in less time.
A New Standard for Digital Production
Repacorp’s first investment in the BOBST DIGITAL MASTER 510 marked a turning point. The all-in-one digital press was able to take on high-SKU, high-volume work with far less waste, downtime, and complexity than traditional or piecemeal hybrid solutions.
“We’ll put a job on press that’s half a million labels with 13 different SKUs—and with BOBST, there are no plate changes, no downtime, and significantly less waste,” said Aaron Dumke, Vice President of Packaging at Repacorp. “That’s a huge advantage in our space.” The decision to partner with BOBST stemmed from the need for a fully integrated system—printing and converting in one pass, from one manufacturer.
“We’ve worked with hybrid presses before, but they’ve always involved multiple vendors. Getting everything to talk to each other was a constant challenge,” added Andy Heinl, Vice President of Digital Labels. “What made BOBST different was that it’s all built in-house. One company, one solution, one support system.”
Speed and Simplicity, Proven
Since installing the first DIGITAL MASTER 510, the difference has been clear. Dumke shared an example: “We ran a job for one million labels with 15 SKUs. It used to take 24 to 25 hours on our flexo press. With the BOBST, it took 10.”
After only four months of production on the first DIGITAL MASTER 510, the measurable productivity gains, new business opportunities, and improved competitiveness led Repacorp to invest in a second press. “Every time we quote a job with the BOBST, we’re competitive. That made the decision to move forward with a second machine an easy one,” said Dumke.
Built-In Support, Built for the Future
Service and support were also major factors in Repacorp’s decision. “We had a few challenges early on, but BOBST stood behind the press,” Dumke explained. “They responded quickly, worked with our team, and weren’t afraid to say when something was on our end. That honesty helped us get better, faster.”
For Heinl, BOBST’s long history in the industry provided critical peace of mind. “We’ve dealt with other manufacturers that were acquired or changed direction, and suddenly we couldn’t get parts or service. With BOBST, we know they’ll be here for the long run—and that matters when you’re investing in a press of this size.”
A Competitive Edge
Repacorp’s digital strategy isn’t about chasing trends—it’s about staying ahead of demand. With two DIGITAL MASTER 510s, the team now has the ability to run complex jobs from raw roll to finished product, including turret rewinding—all in one touch. “We’ve created a system where we can go straight from the mill to shipping,” said Dumke. “That’s a huge benefit not just for us, but for our customers.”
As Repacorp continues to expand its capabilities, the team is already planning to document real-time data and benchmarks to further showcase the performance gains achieved with BOBST technology. “We’re not just doing digital short runs. We’re doing large-volume, multi-SKU prime labeling—and doing it efficiently,” said Heinl. “That changes the conversation with customers.”