What Can Go Wrong—and Why
Most failures trace to seal integrity, under-spec’d films, or misaligned equipment. Fixing root causes early saves rework, scrap, and customer goodwill. For a holistic view of costs and savings, see the pillar.
Common Problems and Risks in Liquid Pouch Packaging
Prevent leaks, downtime, and reputation hits with the right films, seals, and equipment settings. For context and benefits, start with the pillar guide.
ESTIMATE MY PROJECT COST
Hidden Cost Impacts
- Scrap & Rework from leaks or weak seals
- Downtime from jams or misfeeds at the filler
- Returns & reputation damage from in-market failures
- Sustainability penalties if structures misalign with goals
Quantify tradeoffs using the cost model outlined in the cost breakdown and pillar.
Risk Areas & Mitigations
- Sealing Quality: Validate dwell/temperature; run burst and vacuum tests.
- Equipment Fit: Confirm spout specs, film slip, and web handling.
- Perception: Highlight convenience, resealability, and sustainability data.
- Recycling Clarity: Choose mono-material where possible and label clearly.
Seal Failures Turned Around
A nutrition drink brand cut leak rates from 4% to <0.2% after optimizing laminate selection and seal parameters, while boosting line speed by 25%.
See more examples in case studies and baseline benefits in the pillar.
Avoid costly trial-and-error by auditing films, seals, and equipment upfront—then explore the full economics in the pillar guide.
ESTIMATE MY PROJECT COST