The Complete Guide to Co-Pack Software
Read on to learn how the right co-pack software helps contract packagers serve customers better, protect margins, and grow, and why so many co-packers are moving off spreadsheets and paper to get there.
Contract packagers operate in one of the most demanding corners of manufacturing. Every brand customer arrives with its own specifications, timelines, and compliance requirements, and the mix changes constantly. Winning that work is one thing. Running it profitably, at speed, across multiple lines and sites, is another.
For more than 20 years, the co-packers who scale have had one thing in common: they replaced manual, disconnected processes with software built for the way they actually run. This guide covers what co-pack software is, the challenges it solves, the hidden cost of manual data entry, and how to choose and onboard the right system.
What Is Contract Packaging?
Contract packaging, often referred to as co-packing or contract packing, involves outsourcing the packaging process to a third-party provider. By leveraging these partnerships, companies such as FMCG brands can focus on product development, innovation, and marketing, while leaving the specialty of packaging to specialized experts.
Contract packaging is closely related to, and often overlaps with, contract manufacturing, where a third party also produces the product itself. Read more about contract packaging as an industry.
What Services Do Contract Packagers Offer?
Contract packagers can handle various tasks, including filling, labeling, kitting, and assembling products, tailored to the specific needs of their clients. By working together with these experts, businesses can enhance their operational efficiency and tap into innovative packaging solutions that may not be feasible in-house.
The category spans secondary packaging such as multipacks and display-ready cases, kitting and fulfillment, light assembly, and quality inspection. Learn more about the roles and services offered by contract packagers.
What Challenges Do Co-Packers Face Every Day?
Co-packers operate in highly dynamic environments where variability is the norm. One of their biggest daily challenges is managing ever-changing demands from multiple brand customers, each with unique requirements, timelines, and compliance standards. This often leads to complex production scheduling, frequent line changeovers, and tight turnaround times.
At the same time, many co-packers still rely on manual processes or disconnected systems, making it difficult to maintain real-time visibility into operations, labor utilization, and inventory. The result is increased risk of errors, delays, and missed deadlines, especially when handling high-mix, low-volume production runs.
Another long-term challenge is maintaining quality and compliance while operating at speed. Co-packers must adhere to strict customer specifications and regulatory guidelines, such as traceability in food and beverage, all while ensuring accurate documentation and audit readiness.
Labor constraints add another layer of difficulty, as onboarding and training temporary or seasonal workers can impact productivity. Limited integration with customers' systems creates communication gaps, leading to delays in approvals, changes, or data sharing. Altogether, these pressures make it hard for co-packers to scale efficiently, protect margins, and consistently deliver high service levels.
What Is Manual Data Entry in Co-Packing?
Manual data entry in contract packaging refers to production workers physically recording inventory, quality, or operational data. These workflows typically involve filling out paper forms and whiteboards, or manually typing into spreadsheets. Because of the time and effort involved, they are often done after a shift or order run is completed, introducing the possibility of lagging data and entry errors.
While manual data entry is common in manufacturing environments, these processes are slow, error-prone, and limit the flow of manufacturing data across departments and between customers and partners. They also take up valuable time in each employee's day.
"We used to run our operations in an Access database that was manual; everything was printed out. Before Nulogy, it was hard to tell what labor we needed on what line." Michelle Stringer, Senior Business Manager, BCI Packaging
What Types of Co-Packing Data Are Manually Entered?
Data is entered manually at every stage of the co-pack production lifecycle: from inventory and production to labor management, maintenance, and quality and compliance records. These inputs are typically captured on paper or spreadsheets and later transferred into systems, which can cause delays, errors, and gaps in data visibility.
Inventory & Materials
- Material usage and consumption
- Lot and batch numbers
- Stock counts and cycle counts
- Receiving and shipping logs
Labor & Workforce
- Employee hours and attendance
- Job assignments and task tracking
- Productivity per worker or line
- Overtime and shift logs
Production
- Units produced per shift or hour
- Scrap and rework quantities
- Work order completion status
- Line speed or throughput
Machine & Equipment
- Downtime events and reasons
- Machine start and stop times
- Maintenance logs
- Equipment performance checks
Quality & Compliance
- Inspection results, pass or fail
- Batch and lot traceability records
- Cleaning and sanitation logs
- Regulatory documentation
Shipping & Logistics
- Shipment quantities and documents
- Bill of lading details
- Delivery confirmations
- Pallet and case counts
What Are the Risks of Manual Data Entry in Co-Packing?
Manual data entry introduces significant operational, financial, and compliance risk through human error, delayed visibility, and fragmented data. These risks lead to poor decisions, quality issues, regulatory exposure, and reputational damage.
Human errors such as missed entries, incorrect values, or inconsistent formats can compromise everything from inventory accuracy to production reporting. Because data is often recorded after the fact, it creates delays in visibility, preventing teams from addressing downtime, defects, or supply shortages in real time. The consequences are slower decision-making, lower productivity, and higher operating costs.
These challenges compound in regulated environments, where incomplete or inaccurate records weaken traceability and increase the risk of non-compliance, audit failures, and costly recalls. Manually captured data tends to exist in silos, such as paper logs or disconnected spreadsheets, which hinders scalability for growing businesses. This "digital disconnect" is one of the biggest challenges facing co-packers, and many are not even aware of the damage being done. Read more in our post on the digital disconnect and the MOS.
What Are the Alternatives to Manual Data Entry in Co-Packing?
Digital systems are the main alternative to manual data entry in contract packaging. Commonly used software includes warehouse management systems (WMS), manufacturing execution systems (MES), quality management systems (QMS), enterprise resource planning (ERP), and Manufacturing Operating Systems (MOS). These are generally implemented to reduce human error and improve visibility and productivity.
However, most of these systems are limited to a specific function or area of operations. Co-packers usually adopt multiple systems to cover their entire business, which means managing multiple vendors and software types, adding cost and time to the operating budget.
Unlike other software, Manufacturing Operating Systems stand apart because they connect data across departments and functions, such as linking quality and maintenance data to production data. By connecting these silos, co-packers gain a more complete picture of their operations and can make better decisions. Learn more about choosing the right software for your co-pack operation.
"Being Powered by Nulogy signals to our clients that Summit isn't just a vendor; we're an integrated, intelligent expansion of their supply chain." Adam Walker, CEO, Summit Packaging Solutions
How Do Co-Packers Benefit From Adopting Software?
Co-packers have much to gain from phasing out manual processes in favor of a complete software system.
First, a MOS centralizes data and standardizes workflows, providing a single source of truth across production, quality, and inventory. Unlike spreadsheets, which are prone to entry errors and inconsistencies, a MOS ensures data accuracy and real-time production monitoring, enabling faster, more informed decisions.
Second, a MOS automates repetitive tasks and standardizes processes, reducing manual entry, human error, and delays from lagging data. Features like production scheduling, quality management, and inventory tracking streamline operations and free staff to focus on higher-value work.
Finally, a MOS supports scalability and continuous improvement. Analytics and dashboards identify bottlenecks, measure performance, and track KPIs over time, capabilities that are difficult to achieve with spreadsheets. See how a MOS solves the top co-packer pain points.
What Is a Manufacturing Operating System (MOS)?
The Manufacturing Operating System (MOS) is a software platform built specifically to solve the digital disconnect facing co-packers and enhance workforce capabilities. Unlike ERP, MES, or WMS, the MOS is a single system that builds off a manufacturer's existing solutions to support smarter, more efficient manufacturing, co-packing, and distribution.
With the support of a MOS, co-packers can connect their data for smarter business decisions, respond faster to the market, and make life easier for the people who plan, produce, and deliver. For co-packers, the MOS starts with Nulogy Shop Floor and expands as needs grow. Learn more about the capabilities and functions of a MOS.
What Are the First Steps to Onboarding Co-Pack Software?
Onboarding a new system begins with defining objectives and success metrics. During planning, co-packers should identify the problems the MOS will solve, such as reducing manual data entry, improving quality processes, or optimizing scheduling, and set realistic, measurable KPIs. Establishing these goals upfront keeps the implementation focused and aligned with business priorities.
Next, prepare people and processes for the change. This involves assembling a cross-functional team from operations, quality, IT, and production, auditing existing workflows, and vetting data for accuracy so the MOS can meet operational needs and integrate with existing systems.
Finally, training and continuous improvement drive adoption and value. Staff should receive role-based training and access to educational resources and support teams, while regular reviews of KPIs and operational feedback refine adoption over time. Read more about how the right support team can ensure smooth implementation and onboarding.
"When we implemented Nulogy, our pallet location and inventory accuracy became significantly better. We didn't need to spend hours trying to find certain pieces of material to bring to the line." Ryan McWethy, Plant Manager, MSI Express
Why Choose Nulogy for Your Co-Pack Environment?
For more than 20 years, Nulogy's software has accelerated growth, efficiency, and output for hundreds of contract packaging sites around the world. From growing businesses to established, multi-site operations, Nulogy is the definitive software platform for managing co-pack operations.
We understand the complexity of your business and the challenges you face every day. Our support and implementation teams are knowledgeable and hands-on, and Nulogy connects co-packers with the brands they serve through supplier collaboration, so both sides plan and execute on the same data.
Co-Packers Growing on Nulogy
Results from contract packagers who moved off manual processes onto Nulogy:
Powered by Nulogy
Summit Packaging Solutions positions Nulogy as an intelligent extension of its clients' supply chains, not just a vendor.
Accurate to the pallet
Bell-Carter Packaging sharply improved pallet location and inventory accuracy after digitizing shop-floor workflows.
Off the Access database
BCI Packaging replaced manual, printed operations and gained clear visibility into the labor each line needs.
Multi-site scale
MSI Express cut the hours spent hunting for materials and lifted inventory accuracy across the plant.
Read more contract packaging success stories, or see what manufacturers say about Nulogy on G2.
Watch and Learn
Unlock the Power of Production Scheduling With AI
Watch a focused deep dive into Nulogy's co-pack and shop floor software, including the role of Nulogy's AI assistant, Nora. Get the full potential of the Production Scheduling module in this recorded session.
Frequently Asked Questions
What is contract packaging?
Contract packaging, often called co-packing or contract packing, is the outsourcing of the packaging process to a third-party provider. Brands use co-packers so they can focus on product development, innovation, and marketing while specialized experts handle packaging, assembly, and fulfillment.
What services do contract packagers offer?
Contract packagers handle filling, labeling, kitting, and assembling products, tailored to each client's needs. Many also offer light manufacturing, quality inspection, warehousing, and fulfillment, giving brands flexible capacity and packaging expertise they do not maintain in-house.
What challenges do co-packers face every day?
Co-packers manage constant variability: changing demand from multiple brand customers, complex scheduling, frequent changeovers, and tight turnarounds. Many still rely on manual or disconnected systems, which makes real-time visibility, labor utilization, quality, and compliance hard to maintain in high-mix, low-volume runs.
What are the risks of manual data entry in co-packing?
Manual data entry introduces operational, financial, and compliance risk through human error, delayed visibility, and fragmented data. It leads to slower decisions, quality issues, and weaker traceability, raising the chance of non-compliance, audit failures, and recalls, and making co-packers hard to scale.
What is a Manufacturing Operating System (MOS)?
A Manufacturing Operating System is a software platform built to solve the digital disconnect facing co-packers. Unlike ERP, MES, or WMS, it is a single system that builds on existing solutions to connect data across production, quality, maintenance, and distribution so co-packers can decide faster.
What software do co-packers use?
Co-packers commonly use WMS, MES, QMS, and ERP systems, but each covers only one function, so most run several at once. A Manufacturing Operating System such as Nulogy Shop Floor connects these functions on one platform, purpose-built for the way contract packagers operate.
Related Resources
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Introduction
Read on to learn all about how the right co-pack software can help contract packagers better serve customers and thrive in the market.
Table of Contents
- What is contract packaging?
- What services do contract packagers offer?
- What challenges do co-packers face every day?
- What is manual data entry in co-packing?
- What types of co-packing data are manually entered?
- What are the risks of manual data entry in co-packing?
- What are the alternatives to manual data entry in co-packing?
- How do co-packers benefit from adopting software?
- What is a manufacturing operating system (MOS)?
- What are the first steps to onboarding a new co-pack software system?
What is contract packaging?
Contract packaging, often referred to as co-packing or contract packing, involves outsourcing the packaging process to a third-party provider. By leveraging these partnerships, companies such as FMCG brands can focus on product development, innovation, and marketing, while leaving the specialty of packaging to specialized experts.
Read more about contract packaging as an industry.
What services do contract packagers offer?
Contract packagers can handle various tasks, including filling, labeling, and assembling products, tailored to the specific needs of their clients. By working together with these experts, businesses can not only enhance their operational efficiency but also tap into innovative packaging solutions that may not be feasible in-house.
Learn more about the roles and services offered by contract packagers.
What challenges do co-packers face every day?
Co-packers operate in highly dynamic environments where variability is the norm. As a result, one of their biggest daily challenges is managing ever-changing demands from multiple brand customers, each with unique requirements, timelines, and compliance standards. This challenge often leads to complex production scheduling, frequent line changeovers, and tight turnaround times.
At the same time, many co-packers still rely on manual processes or disconnected systems, making it difficult to maintain real-time visibility into operations, labor utilization, and inventory. The result is increased risk of errors, delays, and missed deadlines—especially when handling high-mix, low-volume production runs.
Another long-term challenge is maintaining quality and compliance while operating at speed. Co-packers must adhere to strict customer specifications and regulatory guidelines (such as traceability in food and beverage), all while ensuring accurate documentation and audit readiness.
Further, labor constraints in the market add another layer of difficulty, as onboarding and training temporary or seasonal workers can impact productivity. As well, limited integration with customers’ systems creates communication gaps, leading to delays in approvals, changes, or data sharing. Altogether, these pressures make it difficult for co-packers to scale efficiently, protect margins, and consistently deliver high service levels.
What is manual data entry in co-packing?
Manual data entry in contract packaging refers to the process of production workers physically recording inventory, quality, or operational data. These kinds of workflows typically involve filling out paper forms, whiteboards, and/or manually typing into spreadsheets or systems. Because of the amount of time and effort needed to complete these tasks, they are often done after a shift or order run is completed, introducing the possibility of lagging data and manual entry errors.
And, while manual data entry is common in manufacturing environments, these processes are often slow, error-prone, and limit the flow of manufacturing data across departments or between customers and partners. Further, they take up valuable time in each employee’s day.
What types of co-packing data are manually entered?
Data is entered manually in every stage of the co-pack production lifecycle: from inventory and production, to labor management, maintenance, and quality/compliance records. These inputs are typically captured on paper or spreadsheets and later transferred into systems, which, as mentioned above, can cause delays, errors, and gaps in data visibility.
Examples of data types across each manufacturing function include:
Inventory & Materials
Co-pack environments track data related raw materials, components, and finished goods, such as:
- Material usage and consumption
- Lot and batch numbers
- Stock counts (cycle counts, physical inventory)
- Receiving and shipping logs
Labor & Workforce Data
Co-packers commonly track data related to workforce allocation and productivity, including:
- Employee hours and attendance
- Job assignments and task tracking
- Productivity per worker or line
- Overtime and shift logs
Production Data
On the plant floor, co-packers need to track what is being made and how much. Examples include:
- Units produced per shift/hour
- Scrap and rework quantities
- Work order completion status
- Line speed or throughput
Machine & Equipment Data
Co-packers using packaging machinery must monitor equipment performance and utilization using data such as:
- Downtime events and reasons
- Machine start/stop times
- Maintenance logs
- Equipment performance checks
Quality Data
Critically, co-packers must ensure that their products meet specifications and regulatory standards using:
- Inspection results (pass/fail)
- Defect types and counts
- Temperature, weight, or measurement checks
- Audit and compliance checklists
Maintenance Data
Co-packers must monitor equipment reliability and asset management to effectively prevent downtime:
- Preventive maintenance checklists
- Repair history and notes
- Spare parts usage
- Inspection records
Quality & Compliance Data
For regulated industries such as food, pharma, and CPG, co-packers must meet specific production and quality standards:
- Batch/lot traceability records
- Supplier and ingredient tracking
- Cleaning and sanitation logs
- Regulatory documentation (e.g., food safety records)
Shipping & Logistics Data
Upon receiving and shipping orders, co-packers must track outbound and inbound movement of goods:
- Shipment quantities and documentation
- Bill of lading details
- Delivery confirmations
- Pallet and case counts
What are the risks of manual data entry in co-packing?
Manual data entry in co-packing introduces significant operational, financial, and compliance risks due to human error, delayed visibility, and fragmented data. These risks can lead to poor decision-making, quality issues, regulatory risks, and reputational damage.
For example, human errors such as missed entries, incorrect values, or inconsistent formats can compromise everything from inventory accuracy to production reporting. Because this data is often recorded after the fact, it creates delays in data visibility, preventing teams from identifying and addressing issues such as downtime, defects, or supply shortages in real time. The consequences are slower decision-making, lower productivity, and higher operating costs.
Further, these challenges are compounded in regulated environments, where incomplete or inaccurate records weaken traceability and increase the risk of non-compliance, audit failures, and costly recalls. At the same time, manually captured data tends to exist in silos—such as paper logs or disconnected spreadsheets—hindering scalability for growing businesses. These risks create “blind spots” across the manufacturing plant, making it difficult for businesses to maintain visibility, ensure quality, and respond effectively to disruptions.
As a result, this “digital disconnect” is one of the biggest challenges facing co-packers, who may not even be aware of the damage being done to their businesses. Relying on spreadsheets, manual uploads, and other time-consuming workarounds means that the data in every part of a co-pack business is siloed and disconnected.
Read more in our blog post on the Digital Disconnect.
What are the alternatives to manual data entry in co-packing?
Digital systems are the main alternative to manual data entry in contract packaging environments. Examples of commonly used software solutions include warehouse management systems (WMS), manufacturing execution systems (MES), quality management systems (QMS), enterprise resource planning systems (ERPs), and Manufacturing Operating Systems (MOS). These solutions are generally implemented to reduce human error and improve visibility and productivity.
However, these software systems are commonly limited to a specific function or area within a manufacturer’s operations. Co-packers usually adopt multiple systems to cover their entire business, which means they must manage multiple vendors and software types, adding costs and time to their operating budget.
Unlike other software systems, Manufacturing Operating Systems stand apart due to their ability to connect data across departments and functions, such as connecting quality and maintenance data to production data. By connecting these data “silos”, co-packers can gain a more complete picture of their operations, and can make business decisions more effectively.
Learn more about choosing the right software for your co-pack operation.
How do co-packers benefit from adopting software?
Co-packers have much to gain from phasing out manual processes in favor of a complete software system.
Adopting a Manufacturing Operating System (MOS) offers significant advantages over manual processes such as spreadsheets and paper forms. First, a MOS centralizes data and standardizes workflows, providing a single source of truth across production, quality, and inventory. Unlike spreadsheets, which are prone to data entry errors and inconsistencies, a MOS ensures data accuracy and real-time production monitoring and reporting, enabling faster and more informed decision-making.
Second, a MOS automates repetitive tasks and standardizes workflow processes, reducing manual entry, human error, and delays due to lagging data. Features like production scheduling, quality management, and inventory tracking streamline operations and free staff to focus on higher-value activities, improving overall efficiency across the manufacturing plant.
Finally, a MOS supports scalability and continuous improvement. The system provides analytics and dashboards to identify bottlenecks, measure performance, and track KPIs over time—capabilities that are difficult to achieve with spreadsheets. This visibility not only improves responsiveness but also strengthens compliance, collaboration, and long-term productivity.
Learn more about how a MOS can solve challenges faced by co-packers.
What is a manufacturing operating system (MOS)?
The Manufacturing Operating System (MOS) is a software platform that is specifically built to solve the digital disconnect facing co-packers and enhance workforce capabilities. Unlike other software systems such as ERP, MES, or WMS, the MOS is a single system that builds off a manufacturer’s existing solutions to support smarter and more efficient manufacturing, co-packing, and distribution.
With the support of a MOS, co-packers can connect their data for smarter business decisions, respond faster to the market, and make life easier for the people who plan, produce, and deliver.
Learn more about the capabilities and functions offered by a Manufacturing Operating System.
What are the first steps to onboarding a new co-pack software system?
Onboarding a new software system in a co-pack business begins with defining objectives and success metrics. During the planning process, co-packers should identify the problems the MOS will solve—such as reducing manual data entry, improving quality processes, or optimizing scheduling—and set realistic, measurable KPIs to track performance. Establishing these goals upfront ensures the implementation stays focused and aligned with business priorities.
Next, it’s critical to prepare people and processes for the system change. This step involves assembling a cross-functional team from operations, quality, IT, and production, auditing existing workflows, and vetting data to ensure accuracy. This way, the solutions within the MOS can meet operational needs and integrate with existing systems.
Finally, training and continuous improvement drive adoption and value. Staff should receive role-based training and access to educational resources and support teams, while regular reviews of KPIs and operational feedback allow adoption of the MOS to be refined over time. By approaching onboarding systematically—aligning goals, preparing data and processes, and empowering users—co-packers can reduce disruption and maximize the benefits of their new system.
Read more about how the right support team can ensure smooth implementation and onboarding.
Why choose Nulogy for your co-pack environment?
For more than 20 years, Nulogy’s software has accelerated growth, efficiency, and output for hundreds of contract packaging sites around the world. From growing businesses to established, multi-site operations, Nulogy is the definitive software platform for managing co-pack operations.
We understand the complexity of your business, and the challenges you face every day. Our support and implementation teams are friendly, knowledgeable, and supportive.
Unlock the Power of Production Scheduling With AI
Watch a focused deep dive into Nulogy’s co-pack and shop floor software, including the role of Nulogy’s AI tool. Unlock the full potential of our Production Scheduling module in this recorded session.