Designed to reduce reliance on labels, RealSync combines printing, data integration and verification in a single workflow. The platform helps manufacturers and packaging producers manage, print, verify and deliver unique package-level information with greater consistency, simplifying production and supporting more efficient smart packaging operations.

RealSync enables manufacturers to print variable information directly onto packaging during production, providing an alternative to preprinted labels for a wide range of applications. By moving variable content into the production workflow, manufacturers can reduce label and packaging inventories, minimize waste and simplify the management of changing SKUs and product information.

As demand for greater product identification, traceability and packaging intelligence grows, manufacturers are managing increasingly complex data requirements. RealSync brings data management, industrial mono- or color-inkjet printing, machine vision verification and smart packaging technologies together within one scalable production platform.

Print variable information directly onto packaging during production

RealSync manages variable data, prints unique information directly onto packaging at production speed, verifies that the correct information is associated with each package and delivers package-level data for reporting, traceability and downstream use. The platform can operate with an on-premises server, giving manufacturers local control of production data without requiring cloud connectivity.

“RealSync is about making smart packaging practical on the production floor,” said David Pirie, President of Array Technologies. “Rather than treating printing, data encoding, verification and connected packaging as separate processes, we’ve brought them together into one workflow that can be configured around the manufacturer’s application.”

RealSync supports a range of variable and connected packaging technologies, including barcodes, QR codes, SKUs, GTINs, lot numbers, production dates to RFID, Bluetooth Low Energy tag cloud-based asset tracking, GS1 Digital Link and other unique identifiers. Machine vision and RFID verification help confirm that the correct data are associated with each package and create production records for downstream reporting and traceability.

For individual production machine or scaled across larger operations
The platform can be configured for an individual production machine or scaled across larger operations, allowing manufacturers to start with current requirements and expand as these requirements evolve.

RealSync supports applications across packaging, food and beverage, pharmaceutical and other manufacturing environments in which accurate product data and package-level traceability are increasingly a requirement. The platform can help manufacturers prepare for evolving identification and data-sharing requirements, including GS1 Sunrise 2027 and the FDA Food Traceability Rule, while supporting workflows that use GS1 standards, such as GS1 Digital Link.

By connecting production data with the information printed, encoded and verified on each package, RealSync provides a bridge between production-floor operations and broader product-data and traceability systems. Package-level data can be delivered to local, cloud or enterprise systems for downstream use.

At PACK EXPO International, Array Technologies will demonstrate the RealSync workflow and its ability to integrate data, printing and verification in a production environment. Manufacturers can submit their own production data before the show, and Array will prepare a demonstration using their application.