A new customer came to us in the process of rolling out a new product line of cosmetics but struggling with some issues. Like many others, the seemingly lower cost of offshore production in China was tempting and they had had product produced there.

Now sadly were they were experiencing significant product packaging quality issues. Customer returns were costly, but much worse than that; they were losing customers due to the quality problems. This is a premium priced product, even in the cosmetic world, and as such, quality issues are a very significant negative to the consumer.

Two separate product lines were impacted.

In the first case due to adhesive issues, the packaging was simply coming apart. We worked with suppliers to identify an adhesive that could handle the repeated stresses of opening and closing the container and then developed a machine to heat the components, remove the parts, reapply adhesive, and then reassemble the product. Continual verification testing was done to make sure the problem was indeed solved. Thousands of products were remanufactured in a very short time frame in order to meet the customer’s needs.

In the second case, caps that had been applied to the product were cracking in transit and storage. Again we worked with suppliers to identify a correct flip top closure for the product. We then setup a line to remove and replace the problem closures, (we also inserted induction seals as an additional security measure) and processed tens of thousands of containers within days to help the customer meet shipments.

It really grieves us to see companies in the marketplace having problems like this. If you have issues like this happen, we can respond quickly to help you solve the problem.

More importantly, we work with all our clients on their products to make sure that the proper raw materials, assembly procedures, and quality control testing procedures are employed to ensure that these types of issues are avoided. We will work with you to identify any pitfalls and determine the best approach to make sure your products are produced on time, within budget, and of the highest quality.