Portfolio - Accel Inc

14% Shrinkage Reduction Success

Rework

14% Shrinkage Reduction Success

When a retailer faced challenges with returns and mark-out-of-stock handling, Accel implemented a comprehensive solution that reduced shrinkage from 14% to under 1%. Through a custom-developed reverse POS system and automated processes, Accel increased throughput to 25-30k units daily—two-thirds more than the previous supplier. The system tracks all processing errors, from incorrect hanger returns to unauthorized ORM-D shipments. This detailed store-level tracking proved so effective that one client’s loss prevention department featured Accel’s security protocols in a training video for all suppliers.

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Flip Cap Assembly Manufacturing Innovation

Rework

Flip Cap Assembly Manufacturing Innovation

When a client faced a looming production deadline for a newly designed bottle cap, Accel’s engineering team delivered a rapid automation solution in just three weeks. By leveraging 3D printing, custom control modules, and pneumatic presses, we created a one-of-a-kind production line that increased output 14 times over the client’s existing manual press process. The system included visual guides for assemblers to ensure quality placement, allowing the client to meet critical market timelines. The impact allowed a major retailer to place 7.3 million units on shelves on schedule, representing $146 million in revenue at $20 per unit. This case exemplifies Accel’s ability to deliver manufacturing solutions that reduce costs while increasing both quality and efficiency.

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Instant Hot Pack Marketing Campaign Success

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Instant Hot Pack Marketing Campaign Success

When a Fortune 500 healthcare company needed to distribute product samples without premature activation during shipping, Accel engineered a die-cut wrap-around insert creating a protective air cushion. This innovative packaging solution delivered impressive results: over 20,000 assembled samples reached potential customers with a 90% reduction in activation failures. The design not only protected the instant hot packs during transit but also improved hospital distribution efficiency, enabling a successful marketing campaign that balanced cost efficiency with product integrity.

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Assembly Innovation for Vacform Salvage

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Assembly Innovation for Vacform Salvage

When facing flawed vacforms from China, Accel engineered a smart solution instead of throwing labor at the problem. Their team developed a specialized process with 3D-printed press forms and custom assembly stations that reduced worker fatigue while salvaging materials. The results? Damage to client products was eliminated and 560,000 vacforms were recovered that would otherwise have been scrapped. This project showcases Accel’s expertise in hand and semi-automated assembly, transforming a manufacturing challenge into an opportunity for innovation and cost containment.

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Diaper Bag Inspection Quality Control Innovation

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Diaper Bag Inspection Quality Control Innovation

When a global nutritional products manufacturer faced a recall crisis, Accel engineered an automated checkpoint system that prevented bags containing recalled milk from advancing in production. This innovation eliminated human error risks and delivered impressive results–inspecting 90,000 diaper bags in just 9 days, enabling safe bag reuse, and saving approximately $250,000 while accelerating market return time. The solution demonstrated how innovative engineering can simultaneously reduce costs, increase quality, and improve efficiency during recall management.

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Streamlined Healthcare Retail Transition

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Streamlined Healthcare Retail Transition

When a Fortune 500 healthcare service company wanted to expand from hospital/pharmacy distribution into the retail sector, they looked to Accel’s engineering team. The company needed a solution to repack bulk hospital products for individual retail sale. Accel’s engineers created structurally sound primary packaging, multi-packs, and secondary packaging for 40 different wound care and medical devices. The team assembled over 37k units for retail launch, managing all aspects from concept to distribution. This comprehensive solution proved more cost-effective and faster than overseas alternatives.

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Automated Wick Production Breakthrough

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Automated Wick Production Breakthrough

When a client’s automated machinery for producing plug-in air freshener wicks was failing to meet market deadlines, they sought solutions from multiple vendors. While competitors proposed a manual assembly process that made only 5,000 wicks daily at 80 cents each, Accel developed an automated solution. Accel’s process outperformed both the client’s original machinery and competitor proposals, enabling ahead-of-schedule market delivery. The solution not only increased output and efficiency but also reduced costs, exceeding the client’s expectations for their air freshener production needs.

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Luxury Gift Set Ribbon Crisis Resolution

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Luxury Gift Set Ribbon Crisis Resolution

When a high-end beauty client entrusted Accel with assembling premium $250 luxury gift boxes, the team discovered a quality issue—one in three boxes arrived with wrinkled ribbons that threatened the product’s luxury presentation and retail readiness. Within 24 hours of identifying the problem, Accel implemented an elegant yet simple solution: adding an assembly line team member equipped with a flat iron to smooth the affected ribbons. This swift, cost-effective approach avoided expensive equipment purchases while maintaining the deadline and preserving the premium aesthetic. The solution resulted in flawless presentation across all units, on-time delivery despite the unexpected challenge, minimal additional labor costs, and strengthened client trust through transparent problem-solving, demonstrating Accel’s commitment to quality assurance under pressure.

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“Puzzle Piece” Mold System Innovation

Blister

“Puzzle Piece” Mold System Innovation

Accel revolutionized vacform mold manufacturing by investing in 3D prototyping technology capable of building prototypes within 12-72 hours. The engineering team further enhanced efficiency with an innovative “puzzle piece” mold system featuring interchangeable cavities that adapt to different product shapes. This dual innovation significantly reduced aluminum mold costs while dramatically accelerating speed-to-market, bringing gift sets to production in hours rather than days. The solution demonstrates how strategic technological investments combined with clever engineering design can transform manufacturing timelines and reduce costs simultaneously.

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Revolutionary Glue-Free Packaging Design

Gift Sets

Revolutionary Glue-Free Packaging Design

To enhance product aesthetics while eliminating problematic glue usage in gift sets, Accel developed an innovative “snap forms” vacform system. The solution features individual bottles fitting into clear friction-fitting “pucks” that snap into a tracked base within the gift set vacform. This design eliminated the need for hard-to-remove glue, reduced costs by decreasing damaged gift sets, and maintained the product’s visual appeal through the clear puck system, resulting in improved product quality and customer satisfaction.

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Candle and Thin Paper Platform Innovation

Gift Sets

Candle and Thin Paper Platform Innovation

Accel tackled the challenge of inserting mini candles into easily torn, thin paperboard cavities by engineering a precision solution. Our team designed a custom 3D-printed fixture mounted alongside a conveyor belt, allowing the fragile paper insert to be securely supported during candle placement. This innovative approach significantly reduced product damage while ensuring candles were seated at exactly the same depth every time. By combining digital design expertise with practical manufacturing solutions, Accel delivered improved product quality and increased production efficiency by eliminating insertion damage concerns.

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Gift Card Holder Assembly Innovation

Gift Sets

Gift Card Holder Assembly Innovation

Accel solved a precision placement challenge for gift cards by developing a specialized box-opening device that ensured exact card positioning while preserving the protective plastic coating. Combined with an automatic gluing system to secure cards with visible barcodes, this solution significantly reduced damages, maintained product quality, and increased assembly efficiency. This innovative approach transformed a manual process prone to errors into a streamlined operation that delivered consistent results while reducing costs.

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Nested Baskets Packaging Innovation

Gift Sets

Nested Baskets Packaging Innovation

Accel tackled a client’s cost and environmental challenges with imported Chinese baskets through a brilliantly simple solution–nesting smaller baskets inside larger ones. By collaborating with suppliers to reconfigure packaging, we maximized space utilization while reducing corrugated materials and freight expenses. This strategic approach delivered impressive results: lower upstream costs, improved storage efficiency, and decreased environmental impact. This project is a perfect example of how Accel transforms logistical challenges into opportunities for both cost savings and sustainability.

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Ornament Ball Assembly Innovation

Gift Sets

Ornament Ball Assembly Innovation

Accel solved the challenge of stabilizing spherical ornaments during gift set assembly with an ingenious dual-purpose solution. Their engineering team developed a custom ring device that not only stabilized the ball-shaped ornaments on moving conveyor belts but also provided crucial support during closure to prevent plastic cracking. The system was enhanced with a return conveyor for ring recycling, creating a closed-loop process. This comprehensive approach reduced product damage, improved finished quality, and increased production efficiency while maintaining consistent assembly standards.

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Pre-Wrapped Gift Sets Innovation

Gift Sets

Pre-Wrapped Gift Sets Innovation

Accel partnered with a manufacturer to develop a semi-automatic gift-wrapping machine that transformed the client’s packaging process. Their engineering team created specialized fixtures to ensure consistency in hand-tied Tiffany-style bows, maintaining quality while dramatically increasing efficiency. What began as a 500-unit test quickly scaled to over 500,000 finished gift sets. The results were remarkable–costs reduced by over 73%, significantly faster turnaround times, and consistently higher quality finished packages. This solution perfectly balanced automation with handcrafted quality elements to meet tight deadlines while exceeding presentation standards.

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Innovative Free-Standing Gift Basket Solution

Gift Sets

Innovative Free-Standing Gift Basket Solution

Accel tackled a unique display challenge for a client who wanted products to appear naturally arranged in gift baskets while maintaining consistent positioning. The design team engineered a creative solution for difficult-to-secure items, including a bottomless metal sleeve, by creating custom plastic die-cut tabs with notches that clicked into place without adhesives. Wall plugs were ingeniously secured using slots in another die-cut component, repurposing what would normally be discarded packaging elements as functional design features. This innovative approach delivered perfect product placement consistency while reducing waste by incorporating existing packaging components, demonstrating how thoughtful engineering can solve presentation challenges while enhancing sustainability.

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Innovative Display Packaging Solution

Gift Sets

Innovative Display Packaging Solution

When a client needed their product to appear loosely placed in packaging while remaining securely fastened, Accel’s DFM team developed an innovative solution. The team created a wooden fixture with precise spacers to position products on clear plastic sheets, which were then processed through an automated glue machine. This system applied exact glue patterns to adhere the tubes in specific locations. The result achieved the desired “loose drop-in” aesthetic while ensuring products remained firmly secured during transit and retail display.

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200K Defect Prevention Achievement

Club Packaging

200K Defect Prevention Achievement

When a major snack food company faced increasing customer complaints about non-packaging quality issues with their multipacks, Accel implemented a comprehensive quality control solution despite the defects originating at the factory level. The team developed a multi-faceted program that included enhanced training for defect detection, systematic tracking of rejected packages with direct factory reporting, and daily sensory testing. This proactive approach resulted in approximately 200,000 defects being caught before reaching consumers in 2024, significantly reducing customer complaints and improving overall scorecard metrics and client satisfaction.

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Tri-Seal Packaging Efficiency Solution

Club Packaging

Tri-Seal Packaging Efficiency Solution

When food manufacturer Kellanova needed high-quality tri-seal packaging without significant tooling investments and lengthy lead times, Accel engineered a game-changing approach. Our team developed a semi-automated assembly process that eliminated upfront tooling costs while meeting rigorous quality standards. By partnering with local fabricators and applying in-house design expertise, we created a flexible solution that dramatically shortened tooling development from 8-12 weeks to just 2-4 weeks. This innovation enabled faster market testing with minimal order quantities, providing Kellanova a streamlined, cost-effective path to market without compromising quality standards.

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Snack Manufacturing Process Optimization Success

Club Packaging

Snack Manufacturing Process Optimization Success

Accel achieved a sustainable 30% cost reduction for a competitive snack production project through strategic process improvements. By streamlining logistics, optimizing recycling, enhancing workforce training, implementing data-driven forecasting, and conducting Kaizen events, Accel delivered impressive results: 37% reduction in direct labor, 20% in indirect labor, 14% in materials, and a 31% overall case price reduction. This comprehensive approach created a more efficient production model while maintaining quality standards, demonstrating Accel’s commitment to operational excellence.

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100K Cubic Feet Waste Reduction Success

Shrink Wrap

100K Cubic Feet Waste Reduction Success

To address store waste disposal challenges, Accel Inc. revolutionized gift set packaging by replacing bubble wrap with PVC shrink bands. After extensive material testing, the team installed heat tunnels on production lines to ensure proper shrink band application and maintain shipping quality. This solution not only reduced costs but also eliminated over 100,000 cubic feet of bubble wrap waste while significantly decreasing the time store employees spent unpacking gift sets, resulting in improved efficiency and reduced environmental impact.

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Food & Beverage New Product Launch Innovation

Miscellaneous

Food & Beverage New Product Launch Innovation

Accel successfully managed a complex new product launch for a major international food and beverage brand seeking to introduce a revolutionary product with completely overhauled formulation and packaging. Faced with tight timelines, stringent packaging requirements, and an ambitious target of 1,000,000 promotional units, Accel’s engineering team coordinated all aspects of the project—from design and substrate selection to printing and assembly. Through efficient project management and manufacturing innovation, Accel not only met all premium design criteria and distribution deadlines but also achieved such significant cost efficiencies that the brand was able to increase its initial promotional launch by 50% while staying within the original budget.

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Case Studies

View All

Food & Beverage New Product Launch Innovation

100K Cubic Feet Waste Reduction Success

Snack Manufacturing Process Optimization Success

Tri-Seal Packaging Efficiency Solution

200K Defect Prevention Achievement

Innovative Display Packaging Solution

Innovative Free-Standing Gift Basket Solution

Pre-Wrapped Gift Sets Innovation

Ornament Ball Assembly Innovation

Nested Baskets Packaging Innovation

Gift Card Holder Assembly Innovation

Candle and Thin Paper Platform Innovation

Revolutionary Glue-Free Packaging Design

“Puzzle Piece” Mold System Innovation

Luxury Gift Set Ribbon Crisis Resolution

Automated Wick Production Breakthrough

Streamlined Healthcare Retail Transition

Diaper Bag Inspection Quality Control Innovation

Assembly Innovation for Vacform Salvage

Instant Hot Pack Marketing Campaign Success

Flip Cap Assembly Manufacturing Innovation

14% Shrinkage Reduction Success

Blister

“Puzzle Piece” Mold System Innovation

Club Packaging

Snack Manufacturing Process Optimization Success

Tri-Seal Packaging Efficiency Solution

200K Defect Prevention Achievement

Gift Sets

Innovative Display Packaging Solution

Innovative Free-Standing Gift Basket Solution

Pre-Wrapped Gift Sets Innovation

Ornament Ball Assembly Innovation

Nested Baskets Packaging Innovation

Gift Card Holder Assembly Innovation

Candle and Thin Paper Platform Innovation

Revolutionary Glue-Free Packaging Design

Miscellaneous

Food & Beverage New Product Launch Innovation

Rework

Luxury Gift Set Ribbon Crisis Resolution

Automated Wick Production Breakthrough

Streamlined Healthcare Retail Transition

Diaper Bag Inspection Quality Control Innovation

Assembly Innovation for Vacform Salvage

Instant Hot Pack Marketing Campaign Success

Flip Cap Assembly Manufacturing Innovation

14% Shrinkage Reduction Success

Shrink Wrap

100K Cubic Feet Waste Reduction Success