Production line testing is an essential component to the packaging selection process. Even with all the time and effort involved in choosing the right materials, it can be difficult to be certain of a packaging’s performance until it runs on the actual production equipment. However, packaging tests require labor and product and can be disruptive to the line. Although necessary, it’s something most processors would prefer not to have to conduct repeatedly.  

The key to a successful packaging test is careful planning prior to testing. Understanding the test parameters and confirming that the resources are in place when ready to test helps to ensure that the packaging test run is the most accurate, efficient and cost-effective evaluation of the new packaging performance.

Part 1: Defining the Parameters

A successful test starts with clearly outlined goals and objectives. The new packaging has been selected for a specific purpose. It may be a new product that needs to fit seamlessly into the existing production line or solving an issue with the current packaging, like leakers or cloudy appearance. The first step is to understand if the new food packaging solution will accomplish the defined goal.

Additionally, other parameters should also be considered to accurately measure packaging performance. In addition to straightforward indicators like leaker rates, pieces-per-minute or cook yield, subjective observations like pattern or color match can be evaluated. Although perhaps not directly related to the primary reason for the change, the packaging cannot be considered successful unless it successfully addresses these criteria as well.

When reviewing the gathered statistics, processors must identify an acceptable failure rate for this new packaging. Because of the extensive variations in product type and packaging methods, acceptable failure rates may vary. At the very least, it’s important for processors to understand what their current level of performance is so that the new packaging can be evaluated against it.  

Once all of the essential data has been identified and a method for collecting and recording the information is established, the processor is ready to move on to the actual testing phase.

In Part Two, we’ll look at the resources needed to conduct a successful packaging test.