Vendors Berry Global (film), Fresh-Lock (zipper), Dow (resins) and ColorMasters (printing/converting) were all involved…how unusual is this?
Moore: Our manufacturing partner Hearthside Foods was involved on this from a production standpoint. I led the team collaboration with the vendors, which included in-person on-site development work both at Kellogg’s, the suppliers and at Dow. This is atypical of a packaging change project because for this project we involved the resin supplier.
What else was different about the project?
Moore: It was managed end-to-end from the resin manufacturing all the way through to the transportation and customer involvement. It involved a lot of collaboration and partnership between the different players depending on their place in the supply chain.
What was the biggest challenge?
Moore: Compatibility of the film with our existing equipment and ensuring that we maintained the same look and feel of the brand.
Please comment on the R&D timetable.
Moore: The project took about 18 months’ time; validation and shelf-life testing took the longest portion of that time.
What’s been the reception?
Moore: It has been positive feedback. The pouch was the recipient of the 2019 Technology Excellence Award in Snack and Bakery during Pack Expo in September 2019. In January 2020, the pouch was chosen for a Silver Award in Sustainability in the Flexible Packaging Assn.’s 2020 FPA Achievement Awards
What’s a lesson learned you can share?
Moore: Involvement and engagement from all parts of the material spectrum is very important when designing for sustainability.
What advice do you have for other brands and engineers working in flexible packaging?
Moore: With regards to sustainable packaging—there is no one size fits all, it’s really important to understand your consumers’ needs, the level of understanding they have around sustainable packaging and what your vendor partners capabilities are. Also, having a good understanding of the recycling infrastructure in your area or country is important from a design aspect.
What was the most personally gratifying experience from this project?
Moore: Being able to be a part of an important goal for the brand and being able to see it from initial ideation to launch.
Moore: This was a very intense project to lead, but if you were to ask anyone on the team, the one theme you would hear is that everyone gained a deep knowledge about another area of the packaging value chain that they didn’t have previously. We will all use the experience to help further sustainable packaging design in future project work.