Case Study: Enhanced Seal Quality & Manufacturing Efficiency

Packaging Reliability Up 23%: 

Adept Transforms Lid-Sealing Operations

A large yogurt manufacturer came to Adept because their paper-based lids were frequently tearing upon opening, with about 25% of lids removing in two or more pieces. 

Adept helped resolve the issue by improving single-piece lid opening rates from 75% to 98% across all factories. Through root cause analysis, process optimization, and staff training, Adept enhanced seal quality and machine performance, resulting in a better consumer experience and increased operational efficiency. 

By implementing vacuum testing and standardized troubleshooting guides, Adept provided a long-term solution that ensures consistent packaging integrity and improved manufacturing reliability.

Core Challenge Identified: Material Selection and Machine Setup Misalignment

  • The material of the lid and the sealing process on the machine.
  • The client did not have a good understanding of the principle of the sealing material design.
  • There were knowledge gaps in the of the machine and how it created the proper conditions for sealing

Results

  •  Improved sealing across all factories. 
  • Tearing performance was improved from 75% single piece opening to 98%. 
  • Consumer preferred opening of container
  • Increased OE as a result of sealing process optimization in the factory.

 Improved sealing across all factories. 

Tearing performance was improved from 75% single piece opening to 98%. 

Consumer preferred opening of container

Increased OE as a result of sealing process optimization in the factory.

Steps Taken by Adept 

  • Root cause analysis was conducted and an in-depth understanding of the lidding material and the sealing process in the factory was developed.  
  • Factory and R&D staff were trained in the sealing and material technology. 
  • Troubleshooting and Development guides were developed and presented to the factories as well R&D and Engineering.
  • Vacuum testing of seals was implemented on all production lines and is now used to measure seal quality and manage performance in the Factory
  • Sealing Optimization was conducted across all factories and machines.

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