Success Story: Enhanced Seal Quality & Manufacturing Efficiency for a Global Yogurt Brand

Client Overview

A large global yogurt manufacturer engaged Adept to address persistent seal failures across its product line. Packaging defects were increasing consumer complaints, driving up production waste, and threatening the brand’s reputation in the highly competitive dairy market. The client needed a partner who could quickly identify the cause and implement sustainable improvements across all factories.

The Challenge

After internal investigations failed to resolve the issue, the client brought in Adept to conduct a deeper root cause analysis. Two primary contributors were suspected. One related to equipment settings, and one tied to the pouch design itself. With high production volume and tight regulatory standards, the solution had to be both fast and replicable across facilities.

  • Poor tear performance created issues for both consumers and QA inspections

  • Inconsistent sealing was causing product waste and rework

  • Prior solutions attempted to fix symptoms rather than the root cause

Our Approach

Adept led a full root cause analysis and partnered with the client’s engineering team to implement a two-part remediation. We redesigned the pouch geometry and introduced a new sealing jaw face, while simultaneously rolling out an inspection protocol to ensure consistent sealing performance across equipment types.

  • Conducted on-site root cause analysis across multiple facilities

  • Redesigned the pouch to improve material interaction during sealing

  • Developed and tested a new sealing jaw design to reduce variability

  • Implemented a standardized inspection and scoring protocol

  • Provided training and validation support to ensure global rollout success

The Impact

Adept's end-to-end optimization delivered more than just higher numbers:

  • Improved sealing consistency across all factories globally

  • Fewer consumer complaints tied to seal failures or poor tear performance

  • Reduced production waste and rework due to faulty seals

  • Standardized sealing process and scoring system for ongoing QA

This isn't just a fix. It’s a transformation.

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