From sample to pilot: what a packaging switch really involves
The practical steps between choosing a sustainable material and running it on a production line.
Choosing a material is the start of a packaging switch, not the end of it. Between a promising sample and regular production sits a series of practical steps. Knowing them in advance makes the switch faster and far less stressful.
## 1. Start from a short list
Everything that follows takes time and money, so it pays to test only what has a real chance of working. A good shortlist comes from the requirements of the pack, not from the longest list of alternatives. If you have not narrowed the field yet, [start with the application](/insights/post?slug=replacing-plastic-starts-with-the-application).
## 2. Samples
Ask for samples of the exact grade, thickness and format you would buy, not a similar one. Confirm what the sample costs, how long it takes to arrive, and whether the supplier can send enough to run a proper test.
## 3. Tests that match real life
A sample that looks right on a desk can behave differently in use. Check it against the conditions the pack will actually meet:
- **Filling and sealing**, including temperature and speed.
- **Storage and shelf life**, in the conditions your product really sits in.
- **Transport**, including stacking, vibration and humidity.
- **The customer's experience**, from opening the pack to throwing it away.
## 4. The pilot
A pilot is a small production run on your own line. It is where hidden problems appear: a seal that is slightly weaker, a tray that warps in a warm warehouse, a label that will not stick. Plan time to adjust, and agree beforehand what counts as success.
## 5. Supply
Before committing, confirm the basics with the manufacturer: capacity, minimum order quantity, lead time and where the material is made. A material that cannot arrive on time at your volume is not a solution yet.
## Where we help
We coordinate the steps above with relevant manufacturers: samples, refinements to the pack design, pilots and supply arrangements, so you deal with one team instead of many. When you are ready to move from a shortlist to a sample, [get in touch](/contact).
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