Enhanced Product Protection & Manufacturing Efficiency
Client Overview:
A leading HCT/P biologics company specializing in allograft solutions engaged Adept after experiencing significant packaging failures. Pinholes were developing in flexible primary packaging following exposure to simulated distribution conditions, with failure rates reaching approximately 40%.
Because these pinholes were detected post-distribution simulation, they were likely occurring in the field, creating potential sterility risk and product loss.
The organization needed a solution that would eliminate distribution failures while improving manufacturing efficiency and reducing cost.
Challenges:
The existing packaging configuration presented both material and process limitations:
- The primary package utilized FEP film, which performs well at extreme cold temperatures but is brittle and susceptible to stress cracking
- Products were shipped at 2–8°C, making extreme low-temperature performance unnecessary
- FEP required very high sealing temperatures, contributing to manufacturing inefficiency
- The packaging configuration included multiple nested pouches (two chevron pouches and two outer pouches), folded prior to cartoning — increasing stress points and handling complexity
The result was a fragile system prone to damage during distribution and inefficient to manufacture.
Our Approach:
Adept applied a structured engineering and root-cause methodology to redesign the packaging system:
- Conducted root cause analysis to identify both material-driven and process-related contributors to pinhole formation
- Redesigned the packaging configuration to eliminate stress-inducing folds and handling pressure points
- Replaced the brittle FEP primary film with an EVA film that met strict cell viability testing criteria
- Simplified the packaging architecture by placing the flat pouch into a protective foam cradle within the carton
- Modified sealing parameters to dramatically reduce cycle times and improve manufacturing throughput
The redesign focused on both distribution durability and production efficiency.
Impact:
The optimized packaging system delivered measurable performance and operational improvements:
- $15–$20 cost savings per package
- Sealing time reduced from 3 minutes to 3–5 seconds, significantly improving productivity
- Zero failures in simulated distribution testing
By addressing both material selection and structural design, the client eliminated sterility risk, improved manufacturing speed, and reduced total packaging cost, transforming a high-failure system into a stable, scalable solution.
Let’s Talk Efficiency Gains
Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.