Barrier · OTR / WVTR permeability
RO EN DE
Bring Your Idea

From your idea to a packaging on the shelf

Nine steps in four phases: discovery, development, validation and launch. Each step has one department that leads it and ends with a decision; we go on only when you approve the result.

Start a project

Who does what, step by step

Leads Contributes Approves
Department / step
01
02
03
04
05
06
07
08
09
KL Client
AM Account management department
IA Purchasing department
KA Quality department
RA Reproduction department
Phase 1 Discovery
01
Discovery

The idea and the brief

We start from your product, not from a material.

  • The product, the target shelf life and storage conditions
  • The packing machine, format and running speed
  • Annual volumes and target launch date
  • Non-disclosure agreement, if needed
Output Technical brief confirmed in writing Gate Brief approved, on to the quotation
Who takes part
KL AM IA KA RA
AM
Account management department Leads
Runs the meetings and writes the brief
KA
Quality department Contributes
Checks technical and food-contact requirements
KL
Client Contributes
Describes the product and machine, confirms the brief
02
Discovery

Feasibility and quotation

What is possible, how fast and at what cost.

  • What is technically possible and what is not
  • Packaging type: flow-pack, pouch, lid, thermoforming
  • Cost and lead time for the prototype and the series
Output Quotation for the prototype and estimated series price Gate Quotation accepted
Who takes part
KL AM IA KA RA
AM
Account management department Leads
Builds the quotation and discusses it with the client
IA
Purchasing department Contributes
Requests prices and lead times from producers
KA
Quality department Contributes
Confirms technical feasibility
KL
Client Approves
Accepts the quotation
Phase 2 Development
03
Development

Structure design

The right structure, not the most expensive one.

  • Required barrier (OTR, WVTR), derived from the shelf life
  • Two or three candidate structures, compared
  • Recyclability and downgauging options
  • Choosing the right producer from our supplier group
Output Structure specification: layers, gauges, target barrier Gate Structure approved
Who takes part
KL AM IA KA RA
KA
Quality department Leads
Calculates the barrier and proposes the structures
IA
Purchasing department Contributes
Selects the producer for the chosen structure
AM
Account management department Contributes
Presents the options and cost differences
KL
Client Approves
Chooses the structure
04
Development

Prototype and trial reel

The first physical material.

  • Ordering the trial reel from the producer
  • Dimensional check: width, diameter, core, winding
  • Archiving the reference sample at BarrierLab
Output Trial reel and archived reference sample Gate Reel conforms, on to testing
Who takes part
KL AM IA KA RA
IA
Purchasing department Leads
Orders the trial reel and follows the lead time
KA
Quality department Contributes
Checks the reel on receipt and archives the sample
05
Development

Laboratory testing

Numbers, before any production run.

  • Test set defined per product: mechanical, barrier, sealing
  • Comparison against the structure specification
Output Test report with method, conditions and results Gate Report approved
Who takes part
KL AM IA KA RA
KA
Quality department Leads
Runs the tests and issues the report
AM
Account management department Contributes
Explains the results to the client
KL
Client Approves
Approves the report
Phase 3 Validation
06
Validation

Trial on your line

Running trouble-free on your machine.

  • Run at production speed, with our technician present
  • Fine tuning: temperature, time, pressure, forming
Output Trial record with the running parameters Gate Material validated on the line
Who takes part
KL AM IA KA RA
KL
Client Leads
Provides the line, the product and the operators
KA
Quality department Contributes
Attends the trial and records the parameters
AM
Account management department Contributes
Schedules the trial and follows up the conclusions
07
Validation Printed packaging only

Artwork and print preparation

For printed packaging.

  • Receiving the artwork and the machine drawing
  • Print tolerances, winding direction, eye mark
  • Flexo or rotogravure, depending on the run
  • Colour proof and PDF approval
Output Signed proof and final print files Gate Proof approved
Who takes part
KL AM IA KA RA
RA
Reproduction department Leads
Prepares the print files and the colour proof
AM
Account management department Contributes
Passes on the artwork and corrections
KL
Client Approves
Signs the proof
Phase 4 Launch
08
Launch

Approval and first production

From prototype to series product.

  • The acceptance specification, signed by both sides
  • The firm order and the production run
  • Incoming quality control, certificate of analysis per batch
Output First conforming delivery, with a batch certificate Gate Acceptance specification signed by both sides
Who takes part
KL AM IA KA RA
IA
Purchasing department Leads
Places the order and follows production
KA
Quality department Contributes
Checks every batch on receipt
AM
Account management department Contributes
Confirms the order and delivery date
KL
Client Approves
Issues the firm order
09
Launch

Stock, delivery and follow-up

Continuous supply after launch.

  • Stock managed in Cluj and Bucharest, based on your forecast
  • Delivery with carriers qualified for packaging materials
  • Periodic review: complaints, costs, optimisations
Output Supply based on your forecast Gate Periodic review or a new project
Who takes part
KL AM IA KA RA
AM
Account management department Leads
Follows the forecast and the account
IA
Purchasing department Contributes
Replenishes the stock
KA
Quality department Contributes
Handles complaints and quality trends
KL
Client Contributes
Sends the forecast and market feedback