Trial Failures Are Avoidable: 5 Common Pitfalls in Packaging Trials & How to Prevent Them

August 21,2025 Category: Packaging Development, Quality Optimization

Plant trials are designed to reduce risk, but when mismanaged, they become a source of it. A failed trial can cost thousands in wasted product, delay timelines, damage supplier relationships, and erode team confidence. While some level of unpredictability is natural in innovation, many plant trial failures share the same preventable causes. 

Below, we break down five of the most common reasons trials go wrong and how to keep your next trial on track from the start. 

1. Assuming Everything Will Work as Expected 

The Pitfall: 

One of the quickest ways to derail a trial is walking in with assumptions about material performance, equipment compatibility, or supplier reliability. Even packaging components with the same spec sheet (e.g., weight, thickness, resin type) can perform very differently depending on the raw material source or production method. 

How to Prevent It: 
  • Test variables independently to rule out root causes in advance.
  • Review historical trial data if available.
  • Avoid relying solely on supplier-provided performance claims—verify them on your own equipment. 

2. Inadequate Supplier Vetting 

The Pitfall:

New suppliers often only get one chance to make a good impression. If they’re not thoroughly vetted before trial, that single opportunity can result in wasted product, poor line performance, or delayed launches. 

How to Prevent It: 
  • Conduct pre-trial testing of materials on the actual line.
  • Review quality documentation and acceptable tolerance for components like cartons or films. 
  • Ensure suppliers understand the application environment and performance expectations. 
  • Establish strong communication channels early. Don’t wait until the trial floor to start collaborating. 

Remember: One shot is all it takes to build, or break, trust.

3. Lack of On-Site Technical Support 

The Pitfall: 

When issues arise during a trial, and they almost always do, not having the right people on the floor can make or break your response time. Packaging engineers, equipment experts, and supplier reps should all be present to identify issues and adapt in real time. 

How to Prevent It: 
  • Include cross-functional support during all phases of the trial. 
  • Make sure your team knows who owns what decision and who to escalate to. 
  • Encourage open, collaborative problem-solving on-site. 

Bonus: This is also a chance to build rapport between brand, manufacturer, and supplier teams, setting the tone for future collaboration. 

4. Poor Communication with Contract Manufacturers 

The Pitfall: 

Your packaging might be designed for your equipment, but that doesn’t mean it works flawlessly at your contract manufacturing partner’s facility. Line speeds, equipment types, tolerances, and automation capabilities can vary significantly from one location to another, leading to unexpected issues during trials. 

How to Prevent It: 
  • Share detailed packaging specifications, including material tolerances, ideal run settings, and any known compatibility issues. 
  • Align early on success criteria and expected outcomes. 
  • Conduct joint planning meetings to ensure both teams understand the line setup, timing, and specific needs of the packaging format. 

Pro Tip: Ask your contract manufacturer what’s worked (or failed) for similar products or formats; They often have valuable insights that can help avoid trial delays or failures. 

5. Skipping Pre-Trial Planning and Documentation 

The Pitfall: 

Without thorough planning, trials quickly become chaotic. When roles, timelines, and objectives aren’t clearly documented, teams default to reactive mode—and the chance to learn and iterate is lost. 

How to Prevent It: 

  • Document goals, KPIs, roles, and responsibilities ahead of time. 
  • Use a trial checklist to track readiness across people, materials, equipment, and data. 
  • Schedule regular check-ins leading up to the trial to ensure alignment and preparation. 

In the world of packaging, plant trials are your proving ground. But a trial shouldn't be about guessing, it should be about validating. Brands that approach trials with rigor, communication, and clarity consistently gain better outcomes, build stronger supplier relationships, and reduce costly surprises down the line. 

The Bottom Line:  

Trial success isn’t just about packaging performance. It’s about how well your teams, and your partners, are set up to succeed together. 

Need support planning or executing your next plant trial? 

Adept Group’s engineering-led packaging experts specialize in trial planning, supplier vetting, and onsite execution support to help you avoid costly errors and maximize trial value. Contact us today.