Is Your Packaging Line a Rework Factory? 7 Warning Signs to Spot Now

Is Your Packaging Line a Rework Factory? 7 Warning Signs to Spot Now

**📋 FREE GUIDE: Crush Rework Chaos** Bring your team together to eliminate unplanned rework with our step-by-step guide.  👉 **Download it now:** https://strategicpackagingpartners.com/crush-rework-chaos In this episode of The Packaging Therapist, we dig into rework—what it is, why it happens, and what you can do about it. From quality risks to cost impact to prevention strategies, we cover everything packaging and operations leaders need to know to turn rework from a daily headache into a rare exception. --- ### ⏱️ TIMESTAMPS 0:00 – Introduction   0:16 – What is Rework? Defining planned vs. unplanned   1:24 – Quality Risks: Where rework introduces safety & spec gaps   4:50 – Building Quality Into Your Line (weight checks, code dates, fiber tear)   5:35 – Real-World Story: The 6-hour timestamp gap   7:05 – Refeed vs. Rework: When rejects can still be saved   8:27 – When Packaging Goes Down: All-hands scenarios   9:19 – The Accumulation/Surge Debate   10:52 – Material Changes: Why "same spec" doesn't mean same results   13:00 – Coefficient of Friction & Environmental Variables   14:27 – Setup Sheets & Preventive Maintenance   16:51 – Tracking Rework: OEE, shift reports & data signals   17:58 – Speak Finance: Putting a dollar figure on rework   20:14 – SKU Rationalization: The true cost of complexity   23:00 – Scrap Rate & Overuse: The 100 pounds in, 98 pounds out reality   24:46 – How Rework Shows Up in OEE   26:44 – Root Cause Analysis & The 5 Whys   29:21 – The Value of Your Quality & Food Safety Team   31:05 – Creating a Positive Shift Culture   33:00 – Cross-Functional Alignment: Packaging meets upstream processing   35:21 – Key Takeaways & Wrap-Up   --- ### 🎙️ ABOUT THE SPEAKERS **Jessie Schwartz**   CEO, Strategic Packaging Partners   Jessie is the CEO of Strategic Packaging Partners, a consulting firm that helps food and beverage manufacturers bridge the gaps between procurement, operations, and packaging engineering. With experience including packaging roles at Target and work with companies ranging from PepsiCo to mid-size food manufacturers, Jessie specializes in cutting through organizational silos and packaging industry complexity to help companies make practical decisions. Her approach focuses on identifying costly blind spots and facilitating the cross-functional collaboration needed to implement packaging solutions that work in the real world—not just in press releases. https://strategicpackagingpartners.com **Tom Hammann**   Food Manufacturing Operations Expert Tom brings over 9 years of food manufacturing leadership experience spanning plant operations, corporate strategy, and continuous improvement. He has held roles including Production & Logistics Team Leader, Business Unit Manager, Operations Manager, and Operations Business Manager at major CPG companies. Tom has facilitated 50+ Value Stream Mapping events and led 100+ cost savings initiatives across internal plants, contract manufacturers, and supplier facilities. His hands-on approach—walking the floor, quantifying waste in dollars, and building quality into manufacturing systems—makes him a trusted resource for tackling operational challenges like rework, scrap reduction, and capacity improvement. --- ### 📌 TOPICS COVERED #PackagingEngineering #FoodManufacturing #Rework #OEE #QualityControl #FoodSafety #ContinuousImprovement #ManufacturingOps #PackagingTherapist #SupplyChain #CPG If you love our content and want to learn more about the packaging industry, hit SUBSCRIBE! Connect with us: www.StrategicPackagingPartners.com  Jessie Schwartz - jessie@stratpackpartners.com

Lab vs. Field: The Compostability Reality Check Your Team Needs

This is a follow-up Q&A session from an IOPP (Institute of Packaging Professionals) webinar featuring Daniel Peretz, Kelly Williams, and moderator Jessie Schwartz.  The discussion addresses questions about sustainable packaging, focusing on bioplastics (particularly PLA), compostability challenges, recycling infrastructure, and the integration of recycled content.  Key themes include the practical limitations of different composting methods, the challenges of replacing fossil-based plastics with sustainable alternatives, consumer education needs, and the importance of setting realistic recycling goals.  The conversation emphasizes that while material science has advanced significantly, infrastructure and market adoption remain major barriers to widespread sustainable packaging solutions. Questions Discussed PLA Compostability: Does PLA break down in windrow compost facilities or home composting, and how do bench chemistry tests correlate with real-world compostability? Fish Box Alternatives: What are alternative options for fish boxes to meet refrigeration requirements while using sustainable materials? Recycling Infrastructure: Why don't more establishments (like fast-food restaurants) have recycling bins despite making sustainability claims? Consumer Confusion: How can the packaging industry address the confusion consumers face with inconsistent recycling labeling and instructions? Pilot Programs for Recycled Content: What pilot programs exist for integrating recycled content, and what approaches are proving successful? Attainable Sustainability Goals: How should brands approach recycled content commitments to make them realistic and achievable? Small vs. Large Scale Partnerships: Do brands need to partner with companies of similar scale, or can smaller companies effectively support sustainability initiatives? About the Expert Panel: Jessie Schwartz, Moderator is the CEO of Strategic Packaging Partners, a consulting firm that helps food and beverage manufacturers bridge the gaps between procurement, operations, and packaging engineering. With experience including packaging roles at Target and work with companies ranging from PepsiCo to mid-size food manufacturers, Jessie specializes in cutting through organizational silos and packaging industry complexity to help companies make practical decisions. She's currently helping numerous brands navigate EPR reporting requirements and has firsthand visibility into how sustainability mandates translate (or fail to translate) into actual operational changes. Her approach focuses on identifying costly blind spots and facilitating the cross-functional collaboration needed to implement packaging solutions that work in the real world—not just in press releases. Daniel Peretz is a resin distributor at NextGen Polymers who works across both virgin and post-consumer recycled materials. His unique position provides unfiltered visibility into market dynamics, supply challenges, and the gap between corporate sustainability announcements and actual purchase orders. He's invested in recycling infrastructure and works with major brands on implementation pilots. Kelly Williams is an independent compostable films consultant with over a decade in the industry, including work with Elevate and Earth First. He's partnered with converters on cutting-edge projects, experienced major market disruptions, and currently develops practical compostable structures designed for commercial scale. If you love our content and want to learn more about the packaging industry, hit SUBSCRIBE! Connect with us: www.StrategicPackagingPartners.com  Jessie Schwartz - jessie@stratpackpartners.com

EPR Is Good For Business

Turn EPR Compliance Into Your Competitive Advantage | Data-Driven Packaging Strategy for Food & Beverage Is your packaging strategy ready for the EPR wave hitting the US? While most companies see Extended Producer Responsibility as just another compliance burden, smart R&D and packaging leaders are using EPR data requirements to drive real business value. In this conversation, sustainability expert Ali Uribe (Founder at Co2ral) talks with Jessie Schwartz (Founder and CEO at Strategic Packaging Partners) where they break down how the same data you need for EPR compliance in Oregon, Colorado, and California can power your carbon calculations, lifecycle assessments, and product innovation decisions. Learn why companies like IKEA reduced glue usage by 70% and cut 3% of their scope 3 emissions just by analyzing their materials data. While this conversation covers the strategic importance of EPR data collection, implementing a systematic approach requires a detailed roadmap. For manufacturers ready to move from awareness to action, our comprehensive guide walks through the practical steps to transform EPR compliance into competitive advantage [https://strategicpackagingpartners.com/harness-your-packaging-data-now-and-outsmart-epr-fees/], including specific data collection frameworks, cost optimization strategies, and real-world implementation examples that can help you outsmart EPR fees while building operational intelligence. What You'll Learn: * Why EPR isn't going away (and why that's good for your business) * How to leverage EPR data for scope 3 emissions and cost reduction * Simple steps to organize packaging data before you're scrambling * Real ROI examples from companies using sustainability data strategically * Practical tools and resources for mid-sized manufacturers Perfect for: Directors of R&D, Package Engineering, and Sustainability professionals at food and beverage companies who want to get ahead of regulatory requirements while driving innovation and cost savings. Stop waiting for the "hurricane to hit shore" – start building your data advantage now. If you love our content and want to learn more about the packaging industry, hit SUBSCRIBE! Connect with us: www.StrategicPackagingPartners.com  Jessie Schwartz - jessie@stratpackpartners.com

Native Sustainability: Turning Waste Into Revenue Streams, with Megan Dobratz

Are logistics and sustainability hurdles blocking your organization's progress?  In this episode, Jessie Schwartz sits down with Megan Dobratz from Native Sustainability to explore innovative solutions for overcoming these challenges. In this conversation, you'll learn: * The role of organizations like Second Harvest in streamlining transportation and storage for perishable goods. * How industrial composting advancements are revolutionizing waste management despite existing complexities. * The impact of technological progress on food recovery and overall sustainability efforts. * Strategies for improving communication within organizations to enhance sustainability initiatives. * The importance of starting with small, actionable steps to foster momentum in achieving your sustainability goals. Tune in to gain insights and practical advice on navigating the intersection of logistics, sustainability, and packaging efficiency. Connect with us: www.StrategicPackagingPartners.com Jessie Schwartz - jessie@stratpackpartners.com Connect with Megan on LinkedIn: https://www.linkedin.com/in/megan-dobratz-leed-ap-58b0a85/ [https://www.linkedin.com/in/megan-dobratz-leed-ap-58b0a85/] Check out Native Sustainability: https://www.nativesustainability.com/ If you love our content and want to learn more about the packaging industry, hit SUBSCRIBE! Connect with us: www.StrategicPackagingPartners.com  Jessie Schwartz - jessie@stratpackpartners.com

Recapping PLMA 2024: Insights and Trends in Private Label Food Manufacturing, with Pamela Derus

Struggling to navigate the complexities of private label food manufacturing? Tune in as host Jessie Schwartz and special guest Pamela Derus, Director of R&D at Heavenly Hunks, recap PLMA 2024 and unlock industry secrets that could save you time, money, and headaches. In this conversation, you'll learn: • How to identify and leverage co-packers to enhance your business's operational efficiency and capacity. • The significance of better-for-you trends in private label food production and the growing demand for gluten-free and organic products. • Inside tips on navigating the intricacies of contract manufacturing, from allergen considerations to production capacity challenges. • The differences between European and American approaches to food manufacturing, and what unique opportunities each offers. • Expert advice on the networking and strategic benefits of attending key industry shows like PLMA. Join us for an enlightening discussion aimed at simplifying your journey in the world of food and beverage manufacturing. Connect with Pamela on LinkedIn: https://www.linkedin.com/in/pamela-derus-a378786a/ Check out Heavenly Hunks : https://heavenlyhunks.com/ If you love our content and want to learn more about the packaging industry, hit SUBSCRIBE! Connect with us: www.StrategicPackagingPartners.com  Jessie Schwartz - jessie@stratpackpartners.com