Digital Quality Control for High Volume Packing

Giving Clients Visibility into Every Packing Run

Lemonpath is an industry-leading contract packing partner, processing over 45 million items annually, including more than 15 million gift packs.

Every packing operation requires detailed tracking and administrative control, including Gold Seal sign-offs, productivity monitoring, team performance tracking, quality control checks, rejects management, and invoicing.

Historically, these activities were managed through standardised paper-based forms. While functional, this process required significant supervisor time to compile end-of-day reports and performance summaries and was naturally more susceptible to manual errors.

To improve efficiency and provide greater transparency, Lemonpath developed LemonTrack, a Power Apps–based tablet application designed to digitise packing line management.

The system allows both operational teams and clients to track packing progress in real time, including:

QC checks and percentage inspected
Productivity by packing line
Quantity packed
Reject tracking with supporting images
Live status of each packing run

By moving to a paperless, live reporting system, LemonTrack enables proactive management of packing lines while giving clients clear visibility into quality, performance, and output throughout the packing process.

Key Features:

Packing Job Setup	Packing briefs, specifications and reference images are stored digitally within the system	Teams have instant access to the correct information, ensuring consistency across every packing run.
Digital QC Checklist	Job-specific quality control checklists are completed directly on tablets during production.	Removes paper records while improving accuracy and traceability.
Rejects Management	Rejected items can be photographed and logged within the system, with images available for client review.	Faster issue identification and resolution with clear visual records.
QC Level Controls	QC inspection levels can be defined per job, from high to low depending on product requirements.	Ensures appropriate quality oversight while maintaining operational efficiency.
Real-Time Productivity Monitoring	Productivity is tracked hourly at individual, table, and job level.	Supervisors can proactively manage packing lines to optimise efficiency and turnaround times.
Automated Invoice Builds	Phase 2 will enable automated invoice generation based on packing activity captured in the system.	Reduces manual administration and improves billing accuracy.

Transforming Packing Operations

The introduction of LemonTrack has transformed how Lemonpath manages contract packing operations. By moving from paper-based reporting to digital, real-time tracking, supervisors can now monitor productivity, QC activity, and packing output live, allowing issues to be identified and resolved immediately rather than waiting for end-of-day reports.

This shift has reduced administrative workload for supervisors and QC teams, allowing them to focus more on managing packing lines and improving operational performance.

Data & Client Visibility

LemonTrack integrates with Power BI, providing structured data and real-time analytics for both internal management and client reporting. Customers can track key metrics including QC checks, productivity, packed quantities, and rejects, creating greater transparency and faster decision-making during live packing runs.

Clients can also access this information directly through a secure portal, giving them real-time visibility of packing progress, QC activity, and rejects imagery as jobs are completed.

Operational Impact

The move to a paperless system has delivered measurable operational improvements:
- 2,200 labour hours saved per year
- £37,500 annual cost savings
- Daily admin time reduced from 2 hours to 60 minutes
These efficiencies help offset rising labour costs while enabling Lemonpath to maintain competitive pricing for customers.

Looking Ahead

Phase 2 of LemonTrack will introduce automated invoice generation, further reducing manual administration and improving billing accuracy.

Team Insight

Adrian Hardy – Contract Packing Director @ Lemonpath

“The Tablet Project has transformed the way we work. Instead of relying on paper forms, we now have real-time information at our fingertips. We can monitor performance hourly and react immediately, rather than waiting until the next day for critical information.”