The challenges of printing and packing recipe cards:
The answer: A recipe magazine, aka The Sun Times
Aggregating all recipes in one magazine immediately solved a number of the above described scaling issues.
For customers: Eliminating card errors drove down customer complaints. In addition, the magazine included bonus recipes, articles about heath and wellness, food culture, and other brand focused materials. Unique themes were developed and showcased for each delivery week. Over a million magazines were delivered in the first year and became popular collectables that could later be found on EBay.
For the company: With no cards to collate for specialized orders, the pack process simplified dramatically and errors were eliminated. Labor previously assigned to sorting cards could now be focused elsewhere in the facility. The customer service saw a dramatic reduction in user complaints. Print waste and over and under-run costs were cut, and pack lines were no longer held up to accommodate emergency printing.