Bridging the Gap Between Film and Machinery in Flexible Packaging.

Executive Summary

In the realm of flexible packaging, the harmony between film structure and machinery is paramount. This case study delves into two real-world scenarios where misalignment between these components led to significant challenges. By examining these instances, we highlight the critical importance of integrated decision-making in packaging processes.

Client Background

• Company A : A multinational corporation (MNC) specializing in agrochemicals, expanding its packaging units across India.
• Company B : A leading Fast-Moving Consumer Goods (FMCG) company in the chocolate and confectionery sector, introducing a new brittle sweet snack to the market.

Challenges

Company A:

• Tasked with packaging 3 kg gusseted bags of agrochemicals for export to Japan.
• Initial trials with Brand A film resulted in pouches opening upon product filling.
• The film supplier attributed the issue to machine design, showcasing defect-free samples from their lab.
• Risked missing their inaugural shipment due to packaging failures.

Company B:

• Aimed to launch a delicate sweet snack requiring robust packaging to prevent breakage.
• Procurement's focus on cost reduction led to the selection of a cheaper film structure.
• Both film suppliers acknowledged the chosen structure was unsuitable for the product's fragility.
• The product launch failed due to leaking bags compromising product integrity.

Results

Company A:

• Successfully met export deadlines with defect-free packaging.
• Established a protocol for collaborative decision-making between film and machinery suppliers.

Company B:

• Faced financial losses and brand reputation damage due to product recall.
• Revised procurement strategies to incorporate technical evaluations alongside cost considerations.

Conclusion

These cases underscore the necessity of a holistic approach in flexible packaging, where film selection and machinery compatibility are evaluated in tandem. Organizations must foster collaboration between procurement, operations, and technical teams to ensure product integrity and successful market delivery.

Key Takeaways

• Integrated Decision-Making: Avoid siloed operations; encourage cross-functional collaboration.
• Prioritize Suitability Over Cost: Ensure film structures align with product requirements, not just budget constraints.
• Conduct Thorough Testing: Implement distribution and shelf life studies before finalizing packaging materials.
• Diversify Suppliers: Engage multiple suppliers to mitigate risks associated with material inconsistencies. (YouTube)

By aligning technical specifications with strategic procurement, companies can enhance product quality, reduce waste, and maintain brand reputation in the competitive landscape of flexible packaging.