Packaging Portfolio Architecture: Rationalizing SKUs to Cut Changeovers and Cost

Packaging Portfolio Architecture: Rationalizing SKUs to Cut Changeovers and Cost

Introduction

Brand portfolios naturally accumulate formats, film structures, and artwork variants over time. Left unchecked, that complexity drives longer changeovers, higher scrap, and slower launches. This guide shows brand owners how to rationalize flexible packaging SKUs, without stifling innovation, so you can cut cost and boost speed.

Why Portfolio Architecture Matters

Complexity Tax: Every extra format or spec requires planning time, inventory, QA checks, and setup. Industry studies show SKU rationalization programs often return margin improvements and faster cycle times by focusing on core SKUs and standard materials.

Operational Signals: If lines struggle to hit OEE or planners carry excess safety stock for packaging materials, it’s usually a portfolio signal, not just a scheduling problem.

Retail Realities: Retailers reward consistency. Fewer form factors make planogram resets easier and reduce shelf confusion while preserving design variety through graphics.

A Pragmatic Framework

Here’s a step-by-step approach to simplify your packaging portfolio:

1. Map the Family: Group products by shared requirements—barrier targets, pack size, reseal needs, and line speeds.
2. Define Standard Structures: Establish “gold specs” with qualified alternates (e.g., PET//PE for stiffness, BOPA//PE-EVOH for oxygen barrier).
3. Decide Format Boundaries: Use evidence—drop tests, transport simulations—to determine when a product needs flat-bottom vs. SUP.
4. Govern Artwork Variants: Consolidate finishes and tie graphic choices to clear business rules (seasonal packs, club sizes).
5. Measure and Iterate: Track changeover minutes, scrap, and late orders before/after consolidation.

Tips from the Plant Floor

• Standardize zipper, hang-hole, and venting options across families to simplify kitting.
• Lock COF guardrails for inside/outside layers to balance belt grip and film sliding; document in specs to prevent drift.
• Use “design-to-line-speed” reviews with co-packers before adding new formats.

Where Layfield Fits

As a vertically integrated manufacturer, we help brand teams consolidate around proven formats (stand-up pouch, flat-bottom, pinch-bottom, lidding films, VFFS/HFFS rollstock) and define spec guardrails that keep performance consistent while enabling qualified alternates.

Ready to streamline your packaging portfolio?

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