Propack quickly became Moonpig’s emergency supplier during the COVID-19 pandemic, managing increased card production with full automation.
A custom system was developed to streamline massive order files, print thousands of personalised cards daily, and ensure 100% match verification.
The entire process was implemented in just 4 days, a task that usually takes several weeks.
The challenge
When the COVID-19 pandemic hit, Moonpig faced unprecedented demand for online greeting cards, while their production capacity was reduced. They needed an emergency contingency supplier to help manage this surge in orders, and Propack came highly recommended.
The objective
Moonpig turned to Propack with the goal of developing a fully automated system to handle the receipt of orders, associated artwork, and the personalised printing of thousands of cards each day.
This presented several challenges. First, the sheer size of the files slowed down our standard SFTP system.
To solve this, our development team built a dedicated SFTP server with a direct 1GB line for faster processing. Another challenge was that Moonpig’s order files were in a format specific to their production facility. We had to adapt the files to generate an additional barcode on the back of each card, which linked to a matching data string on the envelope—ensuring each card was perfectly matched with the correct address.
What we did
In just 4 days, Propack had the entire system up and running, a process that usually takes weeks. After a successful test, we began producing thousands of high-quality, personalised cards per day, with 100% match verification and automated pack completion updates sent directly back to Moonpig.
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