FJC Packaging Consultants

The Challenge A major end-user client was expanding sales into higher-altitude regions. Although they had some existing business in these areas, they began receiving growing complaints from a key customer about pouches arriving “popped” open due to compromised seals.

 

Our Approach We rapidly got to work and set out to

 

• Performed a detailed multi-site assessment that included observing production lines, reviewing machine settings, evaluating quality control procedures, and analyzing returned failed packages.

• Review previous attempts to find a solution to the issue.

• Examine all relative inputs including QC standards, equipment systems, operator training​, and film standards.

• Conduct basic Design of Experiments (DOE) to identify ideal machine parameters for high-altitude performance.

 

Our Findings

• Inconsistent or nonexistent in-process QC testing across manufacturing locations, largely due to recent mergers and acquisitions.

• QC teams were primarily focused on product quality rather than package quality, resulting in minimal attention to seal integrity and hermetic performance.

• Significant variation in equipment age — some facilities running 30–40-year-old machines with minimal maintenance or upgrades.

• QC equipment was frequently mothballed, with operators and QC staff lacking proper training.

• High-altitude materials were being used, but with incorrect heat seal settings and narrower seal heads (installed for material cost savings) that reduced seal strength.

 

Solutions Recommended:

• Standardize basic QC equipment at every site.

• Assign and train dedicated QC personnel for consistent testing and documentation.

• Implement a comprehensive QCIP (Quality Control Inspection Plan) for tracking and auditing.

• Implement a written quality test instruction manual to be followed across all manufacturing sites.​

• Optimize heat seal settings and seal head configurations in collaboration with converters.

• Conduct more detailed Design of Experiments (DOE) to identify ideal machine parameters for high-altitude performance.

• Recommend targeted capital equipment upgrades for outdated machines and seal heads.

• Evaluate new manufacturing locations at altitude to minimize transportation-related seal stress.

 

The Results A detailed report and actionable recommendations were delivered to the client. Due to the recommendations of new equipment as well as an expansion of personnel, the project was put into a capital project track for approval by upper management.

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Project Timeline 5 months