Beverage Industry logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Beverage Industry logo
  • NEWS
    • R&D News
    • Supplier News
  • PRODUCTS
    • New Products
    • Reader's Choice Poll
  • CATEGORIES
    • Alternative Drinks
    • Beer
    • Bottled Water
    • Cannabis Beverages
    • Carbonated Soft Drinks
    • Energy Drinks & Shots
    • Juice & Juice Drinks
    • Plant-Based Beverages
    • Sports Drinks
    • Tea and Coffee
    • Wine & Spirits
  • R&D
    • Beverage R&D Features
    • Ingredient Spotlight
  • PACKAGING
    • New Packages
    • Packaging Equipment
    • Packaging Material
  • OPERATIONS
    • Distribution
    • Plant Focus
  • TOP LISTS
    • Beer Market Report
    • Executive of the Year
    • State of the Beverage Industry
    • Top 100 Beverage Companies
    • Truck Report
    • Wholesaler of the Year
  • MEDIA
    • eBook
    • Podcast
    • Polls
    • Videos
    • Webinars
  • DIRECTORIES
    • Annual Manual
    • Contract Packaging Guide
    • Take a Tour
  • MORE
    • Classifieds
    • Channel Strategies
    • eNewsletters
    • Events
      • Membrane Technology Forum
    • Interactive Product Spotlights
    • Market Insights
    • Sponsor Insights
    • Store
    • White Papers
  • EMAG
    • eMagazine
    • Archived Issues
    • Advertise
  • SIGN UP!
CommentaryPlant Focus

Packaging evolutions can create a domino effect for operations

Supply chain adapt to accommodate refreshed packaging

By John Peter Koss
John Peter Koss
January 16, 2017

Walking through the retail marketplace, observing the myriad beverage packages and visualizing the process that created what now is being observed, the magnitude and complexity of the process becomes evident. Making the current observation and possessing years of experience, it becomes instinctive to make a breakdown of package components, visualize the detail of each operation in the process and analyze the domino effect that takes place whenever packaging changes are made.  

Some examples will illustrate this point. First is the variety of closure sizes/types and the related standard or specialized equipment that could be required to close the package. Second is the wide range of container sizes, types and materials that might be required standard or customized machinery. Third is the various wrapping designs/concepts used to unitize the containers that obviously needed dedicated and/or flexible machinery for the operation. All of these represent the impact of packaging on the producing department in a beverage facility. The significant question in the packaging arena is: Why is all this important?

These issues are important because beverage packaging decision-makers continually are making changes to existing packages and establishing new packages for products. Historically, and realistically, these changes create what has been illustrated as the domino effect in the production segment of the supply chain. Let’s brief the rationale behind the packaging decisions to determine how the domino effect is generated and how it can become a very cost-intensive project.

Packaging people have used the age-old phrase “packaging sells” to justify new entries or the modification of old items. It has been, among others, a prime mover of package changes, often times without adequate basis for proceeding with production. The rationale that packaging is a major factor for consumer acceptance, appeal and success is not an issue; however, changes, with or without justification, can create an expensive and short-lived domino effect.

Packaging changes and the usual domino effect go hand in glove. They have always existed and will probably be on-going priorities. As an example, more than 50 years ago, paper versus foil labels on returnable beer bottles was a project that involved labelers without the flexible capability of handling both types of labels. Cost was an obvious issue, but the project involved machinery manufacturers, label suppliers and material compliance agreements before production could proceed — in fact, it became a domino effect with major capital expenditures. Today, the packaging observations were meant to confirm the validity of a realistic domino effect in beverage packaging with considerably more high-tech complexity, personnel training and capital investment.  

To appreciate the fact that a domino effect usually happens when package changes are made, beverage packaging lines are reviewed to recognize various operations and the management and supplier personnel involved in a project. Even though most packaging changes are originated by parent companies or franchisors, contractors or franchisees usually have a packaging director or team that coordinates major projects to provide justification, specification requirements and adherence to schedules. One of the main concerns here is making sure that the designated producer has the capability and capacity to produce the package (either new or modified old).

For can lines, changes in container, closure or package might involve container handling systems, including lids, filling nomenclature, closing machines, wrapping equipment and casing machinery. For example, going from 12- to 8-ounce cans, a change from steel to aluminum material, closing machine speeds, shrink-wrap tray, or various six- or 12-pack carrier equipment. These are only a few of the many can package changes that will continue to create and perhaps magnify the domino effect.

For bottling lines (glass or non-returnable), returnable glass is somewhat infrequent; however, many are proprietary and could require dedicated machines throughout the line, including closures and labels that also might be proprietary with related special equipment. Non-returnable bottles could require rinsing, filling, closing and wrapping changes depending on the container configuration. In any case, a domino effect actually is created to provide required capability and capacity.

For PET bottling lines, the bottles present a special situation because many producers manufacture their own bottles. In this scenario, the domino effect is different and can be more complex because the producer plays several roles in the project for any PET design change involving container production equipment that normally would not occur. However, in addition to all operations on the normal production line, where the domino effect might not take place, container manufacturing presents a challenge to minimize the impact that inevitably will occur. Plastic packaging volatility and the domino effect will remain an issue.

From an operations perspective, beverage packaging, to some extent, always will create a domino effect in the production segment of the supply chain. BI

 
KEYWORDS: aluminum cans caps and closures plastic bottles supply chain

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

John peter koss beverage industry

John Peter Koss, the beverage operations advisor, has more than 60 years of beverage industry experience, was an operations executive for a Fortune 500 company and can be contacted at bossole2@gmail.com.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • top 100 beverage companies

    Top 100 Beverage Companies of 2024

    For the global beverage market, mergers and acquisitions...
    Carbonated Soft Drinks
  • Chocolate, Strawberry, Vanilla shakes

    Classic flavors provide reliable, consistent results for beverage-makers

    Classic flavors of chocolate, vanilla and strawberry...
    Ingredient Spotlight
    By: Chloe Alverson
  • Free Spirits Instant Bar Bundle

    Lifestyle trends drive growth for non-alcohol category

    As lifestyle trends continue to drive growth for the...
    Wine & Spirits
    By: Lauren Sabetta
Manage My Account
  • eNewsletters
  • Online Registration
  • Subscription Customer Service
  • eMagazine Subscription
  • Manage My Preferences

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the Beverage Industry audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of Beverage Industry or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • Fourpeople toasting with cocktails made with low-sugar ingredients, celebrating healthier drink options.
    Sponsored byCargill

    What’s Hot in Sugar Reduction: Beverages

  • chocolate milk
    Sponsored byCargill

    Sweetening the Future for Dairy and Dairy-Alternative Beverages

  • woman pouring a drink
    Sponsored byFFP

    Building a Beverage System: Meeting Consumer Demand for Precision Wellness

Popular Stories

Sting Energy

PepsiCo, Sting Energy unveil global partnership with Formula 1

PepsiCo + poppi

PepsiCo completes acquisition of poppi

people drinking Wynk

Mindful drinking prompts growth for THC beverages

Top 100 Beverage Companies of 2024

Events

April 16, 2025

2025 State of the Industry Series: Alcoholic Beverages

On Demand In Beverage Industry’s annual State of the Industry: The Alcohol Beverage Market, analysts at S&D Insights LLC delve into these trends and how they’re shaping the industry.

June 26, 2025

FAST. FOCUSED. FUELED: Delivering Energy Consumers Can Feel

Learn how to formulate products that deliver the energy experiences that people want, and keep them coming back for more.

View All Submit An Event

Poll

Retail Coffee Segment

What retail coffee segments will fare well into the next year?
View Results Poll Archive

Products

Milk and Dairy Foods Nutrition, Processing and Healthy Aging

Milk and Dairy Foods Nutrition, Processing and Healthy Aging

See More Products

Related Articles

  • John Peter Koss

    SKUs have domino effect on beverage supply chain process

    See More
  • John Peter Koss

    Case packing operations under constant change

    See More
  • John Peter Koss

    Pre-distribution valuable for supply chain operations

    See More

Related Products

See More Products
  • beer.jpg

    The Chemistry of Beer: The Science in the Suds, 2nd Edition

  • ency brew.jpg

    Encyclopaedia of Brewing

See More Products
×

Elevate your expertise in the beverage marketplace with unparalleled insights and connections.

Join thousands of beverage professionals today. Shouldn’t you know what they know?

JOIN NOW!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing