01
Three parties, one working package
| Party | Information and decisions usually owned |
|---|---|
| Brand | Product, fill, consumer use, shelf-life objective, claims, graphics, forecast, launch timing, commercial approval and acceptable presentation |
| Co-manufacturer | Equipment, change parts, dimensional limits, approved materials, web and roll limits, filling, sealing, line speed, trial process, storage and operating approval |
| Packaging supplier | Manufactured construction, converting capability, dimensions and tolerances, print, pouch or roll requirements, quality documentation, samples, production lead time and material change control |
02
Use the first technical meeting to close the largest gaps
- Confirm the product, target fill, package format, launch volume, timing, and what has already been approved.
- Identify the exact equipment, change parts, filling method, normal speed, and current comparable packages.
- Review the proposed dimensions, usable fill area, headspace, seals, zipper or fitment, and how the package is presented to the line.
- Confirm structure requirements, approved-material restrictions, barrier, sealant, stiffness, friction, and any existing validation.
- Review roll, web, core, repeat, unwind, eye mark, splice, diameter, weight, and lifting limitations when roll stock is involved.
- Define samples, line-trial quantity, scheduling, success criteria, decision owners, and how trial findings become a released specification.
03
Questions for premade pouches
Machine range
What finished width and length ranges, zipper locations, gussets, fitments, and pouch styles can the line accept with available change parts?
Opening and presentation
How are pouches loaded, picked, opened, indexed, held, filled, closed, and transferred? What stiffness, flatness, or stack requirements matter?
Fill and headspace
How does the product enter the pouch, how much dusting or bounce occurs, and what clear area is needed for zipper closure and final sealing?
Final seal
What seal width, temperature, pressure, dwell, cooling, contamination tolerance, and top trim are required?
Pack-out
What filled shape, case count, orientation, compression, labeling, inspection, and pallet pattern are expected?
04
Questions for roll stock
Web geometry
Approved web width, repeat, lanes, unwind, eye mark, print orientation, fold and seal positions, and registration tolerances.
Roll geometry
Core, maximum and preferred diameter, maximum weight, winding, edge alignment, splice rules, roll identification, and handling equipment.
Material behavior
Required COF, stiffness, curl, forming, hot tack, seal window, release, static, barrier, toughness, and compatibility.
Operating window
Normal and target speed, temperature zones, dwell, pressure, tension, forming set, product drop, and known sensitivities.
05
Define the trial before material arrives
A line trial should answer named questions. Agree on the amount of material, setup conditions, variables that may be adjusted, sample collection, measurements, waste tracking, filled-product disposition, and the people authorized to approve or request another trial.
Success criteria can include stable tracking, acceptable speed, registration, opening or forming, fill accuracy, clean seals, leak or seal data, package appearance, waste, changeover time, case pack, and retained samples. The final criteria should reflect the actual risk of the application.
06
Close the handoff with controlled records
Released package specification
Material, dimensions, performance, print, roll or pouch construction, packing, labeling, and revision.
Approved artwork
Correct dieline or web layout, revision, color targets, barcode verification, and approval record.
Operating record
Qualified equipment, change parts, settings or operating window, setup notes, inspection and sampling requirements.
Trial report
Material identity, conditions, changes, output, defects, measurements, samples, decisions, and remaining actions.
Change control
Who must be notified when product, material, package, artwork, equipment, manufacturing location, or process changes.
FIELD CHECKLIST
Information to collect
Use this as a working prompt, then adapt the final specification or validation plan to the actual application.
- Brand permission for direct technical coordination and communication rules
- Product, fill, density, shelf life, format, features, and launch timing
- Exact co-manufacturer location, equipment, change parts, and technical contact
- Approved dimensions and the measurement convention used by each party
- Structure, sealant, barrier, friction, stiffness, and approved-material requirements
- Web, repeat, unwind, eye mark, core, roll, splice, and handling requirements
- Pouch opening, fill, headspace, zipper, final seal, and pack-out requirements
- Artwork geometry, print, barcode, proof, and approval responsibilities
- Trial material, schedule, variables, measurements, samples, and success criteria
- Final specification owner, revision process, and change-notification expectations
COMMON QUESTIONS
Questions worth resolving
What if the brand and co-packer use different pouch dimensions?+
Stop and reconcile the measurement convention before ordering. Finished outside dimensions, inside or usable dimensions, seal-to-seal measurements, gusset descriptions, zipper location, and machine limits may be described differently. Use a marked drawing and physical sample.
When is the packaging handoff complete?+
The handoff is complete when the approved material, dimensions, artwork, roll or pouch requirements, operating assumptions, trial results, approval owners, and change-control expectations are captured in controlled records accessible to the responsible parties.