Finding the source
The problem appeared on the machine. It started with the film design.
The existing package was a laminated barrier film with graphics printed on the outside surface. That construction had originally been selected as a way to control film cost. It provided the required appearance and barrier, but it left the ink exposed to friction, heat, and direct contact with machine components.
The film needed to be designed around the way it was actually being used.
The change
Move the ink away from the equipment.
The package was redesigned as a reverse-printed high-barrier laminate. Moving the ink inside the film structure protected the graphics from contact with the equipment while maintaining the required barrier and seal performance.
Supplier technical specifications were reviewed to confirm the barrier. The redesigned film then went through a full production trial and a scale-up order.
During the trial, the customer confirmed that the ink was no longer transferring onto the equipment. The sealing jaws remained cleaner, the seals performed as required, and the machine could run faster.
The result
Less cleanup. More time producing.
The new film cost approximately 15% less than the previous material.
The customer reported that approximately two hours of additional weekly cleanup were no longer required. The repeated cleaning stops during production were also reduced, giving the customer more running time from the existing equipment.