Many brands run into issues when the packaging supplier and co-packer aren’t aligned, leading to inefficiencies, delays, and added costs.

Without clear communication and upfront technical planning, even the best-designed packaging can fail in production. Poor seals, film incompatibility, or incorrect dielines can result in wasted materials and costly delays. To avoid these pitfalls, it’s crucial to work with a packaging supplier that knows how their packaging material works on various machinery. Here’s how to do it.

1. Outlining Technical Specs for Packaging and Co-Packing Compatibility

Flexible packaging must be designed to work seamlessly with the co-packer’s machinery, sealing process, and the product being packed. This means brands should align on key technical specifications well before production begins.

Key Specifications to Define Early

• Machinery & Seal Dimensions – Confirm the co-packer’s machinery capabilities, including sealing temperature, pressure, and film tension requirements. If the film thickness or material isn’t compatible with the equipment, it could lead to weak seals or production inefficiencies.
• Film Specifications – The selected film must align with the product’s needs, offering barrier properties for moisture, oxygen, and light protection while also running efficiently on the co-packer’s line. A mismatch in film properties can lead to wrinkling, slipping, or tearing during production.
• Dielines & Artwork – Ensuring dielines are formatted correctly for printing and production is crucial. Elements like registration marks, gusset placement, and print tolerances should be aligned with both the packaging supplier and co-packer before artwork is finalized.
• Sample Rolls (If Needed) – In some cases, testing sample rolls before full production helps catch potential issues early, ensuring the packaging performs as expected.

Skipping any of these steps can lead to bottlenecks, requiring expensive last-minute adjustments to either the packaging or the co-packer’s setup.

2. The Role of the Packaging Supplier in Managing Stakeholders

A reliable packaging supplier should work with you in managing technical specifications and ensuring all stakeholders are on the same page.

What a Strong Packaging Supplier Should Do

• Gather all necessary technical specs from the brand and co-packer to confirm compatibility before production.
• Identify potential production challenges early—such as seal strength, film compatibility, or feeding issues—and work to resolve them proactively.
• Facilitate sample testing or trial runs if necessary to ensure the film and packaging materials perform as expected on the co-packer’s machinery.
• Maintain ongoing communication between the brand, design team, and co-packer, ensuring any design or material adjustments are approved across all parties.

By taking an active role in managing these moving parts, the right packaging supplier ensures a smoother production process with fewer disruptions.

Wrap Up

Misalignment between packaging suppliers and co-packers can create costly and time-consuming issues. By working with a trusted packaging partner who proactively manages technical specs and communication, brands can avoid common pitfalls and streamline production.

Josh Packaging specializes in managing packaging projects end-to-end, ensuring the right materials, specifications, and production processes align smoothly with co-packers. This kind of strategic partnership helps brands bring high-quality products to market without unnecessary delays.

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