01
Your packager is leaving.
They have exited the category, or you acquired a brand and the original maker will not keep producing it. We have taken on work other companies walked away from, and we have done it before.
See capabilitiesContract packaging and manufacturing · Corbin, Kentucky
Seven blister lines. Capacity open now.
Most contract packagers answer a capacity question with a lead time. We answer it with a start date. TCO has packed, kitted, stored and shipped non-food consumer products out of one Kentucky facility since 1997.
Non-food only. Programs running six months or longer.
BLISTER LINE RUNNING, WIDE · 16:9
Since 1997Continuous operation
SevenBlister lines, all open
148,500Sq ft under roof
99.85%Inventory accuracy, sustained
You are probably here for one of four reasons.
02
You have run out of room.
Your packager cannot absorb the volume, or your own plant is full. We have open capacity across seven blister lines, floor space and labor. Ask us for a start date rather than a lead time.
See capabilities
03
Your supplier failed.
Quality escapes, missed dates, complaints, sometimes product already sitting in a distribution center or out in the field. Inspection, rework and repackaging is normal business here, not an interruption between production runs.
Rework and recoveryRETAIL READY DISPLAY, ASSEMBLED · 16:9
04
You have a launch, or a retailer you just landed.
A new product that needs packaging built around it, a display program, or shelf space you have never had to pack for. We have packed to big box and automotive chain standards for three decades and we know what those shelves require.
Retail displaysWhat we do.
Packaging as a service, with the warehouse and the freight behind it. We do not sell boxes, film or machines, and we do not design packaging. You bring the product and the artwork. We run the program.
Blister packaging.
Seven lines running face seal, trap seal and seam fusion, including choke hazard sealing.
Kitting and assembly.
Multi component kits built to a bill of materials. Retail multipacks, spare parts, service, installation and dealer kits.
Hand pack, case pack and auto bagging.
Manual packing where a product needs judgment. Automated case packing and bagging where it does not.
Fold and tuck cartons.
Carton erecting, loading and closing for retail and distribution formats.
Retail displays.
Countertop, endcap and pallet displays, assembled and shipped retail ready.
Light manufacturing.
We manufacture as well as pack, where doing so removes a step for you.
Warehousing, 3PL and distribution.
Storage, inventory control, order fulfillment, distribution and direct to consumer shipping.
Rework, RMA inspection and recovery.
Product that has already gone wrong. Inspected, repaired, repackaged and returned.
Custom process and line engineering.
If your product is awkward enough that nobody will quote it, we will design and build the line first.
Most of the country, two days from our dock.
TCO sits in Corbin, Kentucky, with immediate I-75 access. More than 70% of the U.S. population is within a 48 hour truck transit, and roughly one third is within 24 hours.
More than 70%Of the U.S. population
More than 240 million peopleReached from our dock
Within 24 hours: Louisville, KY 128 miles, Cincinnati, OH 151 miles, Nashville, TN 159 miles, Charlotte, NC 217 miles, Columbus, OH 216 miles, Atlanta, GA 222 miles, Indianapolis, IN 225 miles, Pittsburgh, PA 327 miles, St. Louis, MO 353 miles, Memphis, TN 355 miles, Detroit, MI 376 miles, Chicago, IL 389 miles, Washington, DC 408 miles, Baltimore, MD 438 miles. Within 48 hours: Philadelphia, PA 526 miles, Kansas City, MO 589 miles, New York, NY 602 miles, Minneapolis, MN 732 miles, Dallas, TX 775 miles, Boston, MA 787 miles, Miami, FL 806 miles, Houston, TX 817 miles. All figures are straight line miles.
Straight line distances. Transit bands are modeled on federal hours of service limits and are indicative, not a service commitment. Confirm lane specific transit times with your carrier.
Thirty years of numbers, and almost no public record of them.
We spent three decades as the near-exclusive packager for one automotive lighting customer. It made us very good, and it made us invisible. This is the record.
99.85% inventory accuracyInventory accuracy, sustained
98%+ on time in fullOn time in full, when material was on site
15 million units per monthPeak throughput
8,000+ SKUs managed, up from 300SKUs managed
roughly three and a half yearsBetween customer quality complaints at peak volume
received 8:00 AM, packaged and shipped by 3:00 PMEmergency turnaround
You are going to ask who else we have done this for.
It is the right question, and the honest answer is that our reference list is short. We spent thirty years inside one relationship instead of building a list of them. What we have instead is the record above, the processes behind it, and a category of work most packagers turn down.
See the customer recordBLISTER PACKAGE, FACE SEAL FORMAT · 16:9
Five things that are true here and rare elsewhere.
01
Decisions in minutes.
The two people who approve the work are in the building. No committee, no board, no forty-eight hour notice to change a shipment.
02
We are the recovery option.
Rework, RMA inspection, adding the component somebody else forgot, opening and resealing product already in the field. Most packagers decline this work. We do it as a matter of course.
03
Accuracy is run as a discipline.
Barcode scanning, vision systems and cycle count rigor, in an industry that measures itself in parts per million.
04
Capacity now, not next quarter.
Open lines, open floor space, and a workforce that wants the hours. Former employees still call to ask when we are ramping back up.
05
Two days from most of the country.
Immediate I-75 access from Corbin, Kentucky, one day to roughly a third of the U.S. population, two days to more than 70 percent, with four major air cargo hubs in reach.
What we will not quote.
Saying this up front saves us both a conversation.
Food and beverage. Pharmaceutical, drug, medical device and cannabis. Packaging design and graphics, which we do not offer. Paper, molded fiber and compostable blister, which our current equipment will not run. Packaging materials and machines, which we do not sell. One-time runs with no path to repeat, where the tooling and setup cost more than the production run.
If your program is on that list we are the wrong company, and we would rather tell you now than in week three.
What happens when you send us a program.
One.
You tell us what it is. Seven questions, about two minutes.
Two.
Josh Robinson, our Director of Operations, comes back to you.
Three.
We scope it, quote it, and tell you when we could start.
No sales sequence, and no discovery call before somebody has actually looked at the work.
Tell us what you need packed.
If it is non-food and it runs for six months or longer, we want to see it.