Coffee Packaging Case

Example Coffee Company was using Kraft + PET + AL foil laminate doypack bags (250g) for their premium roasted coffee, which included a one-way degassing valve and zipper. The production team used a 4-color rotogravure process for printing and applied lamination with solvent-free adhesive. The QC report indicated that the dimensions of length, width, gusset, and bottom seal were all within tolerance.

However, when the packaging samples were shipped to the customer, they visually reported that the bags looked small, and even after filling, they did not give the expected “full” feel. Investigation revealed that:

• The bag stiffness was high, preventing the gusset and bottom folds from fully expanding.
• In the empty state, the bag appeared small, although the filled capacity was almost correct.
• The combination of lamination and valve placement restricted the bag’s opening angle.
  
  

Question/Problem: The customer perceives the bag as being small, but the technical measurements are accurate. What should the packaging team’s next step be in this situation?