Packaging

Morgan’s packaging professionals have expertise in package development through complete packaging line design, delivering customized solutions that advance your operations

From package design and development to packaging systems engineering and integration, assessments, and troubleshooting, Morgan’s team has the specialized skills to meet your packaging needs. Whether you have a specific package for a new product launch or a CAPEX project for a complete packaging line, we are ready to drive your initiatives forward.

  • Package Design & Development

  • Packaging Engineering

  • Centerlining & Line Balancing

  • Landscape Assessments

  • Recyclability Assessments

  • Package Testing & Troubleshooting

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404-373-5320
Food Packaging Systems in the Food and Beverage Processing Industry

Package Configuration & Material Development

Morgan’s packaging experts collaborate closely with clients to create customized packaging systems that meet the specific requirements across various product categories including:

  • Bakery
  • Beverage
  • Dairy
  • Shelf-Stable Products
  • Frozen and Fresh Items
  • Alternative Packaging Formats

Comprehensive Package Design and Development

Our Package Design and Development professionals specialize in creating packaging solutions that provide product protection and food preservation while delivering on key client requirements:

  • Primary and Secondary Packaging Design
  • Material Cost Optimization and Recyclability
  • Traceability
  • Consumer Perception and Branding
  • Handling and Distribution Best Practices

Expertise in Critical Packaging Technology Areas

Morgan’s packaging technologists and engineers possess broad expertise in critical areas including:

  • Ingredient and Nutritional Labeling
  • Shelf-Life Studies and Testing
  • Material Harmonization and Lightweighting
  • Product-Package Material Interfaces
  • Seasonality Factors Impacting Supply Chains and Distribution Channels

Our solutions are robust, aligning with consumer expectations, retailer requirements, and sustainability goals to meet the demands of a dynamic marketplace.

Enhancing Packaging Operations

Whether expanding operational throughput with new packaging lines or upgrading existing systems, our Packaging Engineers deliver reliable solutions to optimize performance:

Innovative Solutions for Packaging Challenges

Morgan’s approach to packaging is ergonomic and comprehensive. We analyze materials and equipment systems to address unique operational challenges. Our solutions consider:

  • Equipment Layout and Orientation
  • Ease of Changeover and Access
  • Material Laydown Areas and Flow Optimization
  • Integration of Semi-Automated and Fully Automated Systems

Consistent and Scalable Packaging Operations

We deliver packaging operations that meet product requirements and market demands, focusing on:

  • Sustainability - Solutions that are flexible for expansion and support clients’ long-term goals
  • Regulatory Compliance - Striving to ensure that all packaging meets industry standards
  • Cost Efficiency - Optimizing material usage and equipment capabilities

Our packaging solutions are designed to seamlessly integrate into your existing operations, minimize disruptions, and provide the flexibility needed for future growth opportunities.

Comprehensive and Forward-Thinking Packaging Solutions

Morgan’s holistic approach to packaging delivers designs that are functional, operationally efficient, sustainable, and aligned with industry trends. Our comprehensive strategies support the evolving needs of your business, providing solutions that drive success today and build a solid foundation for tomorrow.

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404-373-5320

Extensive Experience in a Wide Range of Packaging Materials & Processes

  • Rigid
  • Flexible
  • Pouches
  • Bottles
  • Cans
  • Aseptic
  • Bag-in-Box
  • Cartons
  • Boxes
  • Drums
  • Totes
  • Paperboard
  • Corrugate
  • Laminates
  • Composites
  • Glass
  • Aluminum
  • Tin
  • PLA
  • rPET
  • PET
  • PETE
  • HDPE
  • Polystyrene
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Driving Results through Project Completion

ESL and Shelf Stable Technologies Co-Manufacturer Search

A client engaged Morgan to conduct an extensive, confidential search for US Co-Manufacturers capable of processing and packaging a new dairy-based nutritionally enhanced fluid milk product. The project was a fast-track effort to create a competitive advantage. Morgan’s scope was to identify solutions for either aseptic or extended shelf life (ESL) 2-liter packaging. Morgan assembled a team of Aseptic SME’s to conduct technical capability assessments over a wide range of options for primary package materials and configurations, keeping the client’s identity confidential throughout the entire evaluation process. Morgan investigated options including ESL Plastic and Paperboard with chilled distribution, Shelf Stable Plastic and Paperboard with ambient or chilled distribution, and combination technologies such as Bag-in-Box. Morgan’s team provided an overview of the Aseptic and ESL technology landscape and identified the commercially available technologies that met the rigors of processing protocols for consumer protection. Morgan gave the client frequent progress updates and presented very detailed information about each supplier’s and co-man’s capabilities in a summary table and call notes. The final comprehensive report delivered by Morgan’s team evaluated and recommended methods for processing and packaging the product. Upon approval by upper management, the client directed Morgan to create a formal presentation suitable for review by the executive leadership team.

Automated Case Packing

A snack foods client was facing challenges due to several manual case packing stations still in operation, leading to hiring difficulties, high labor costs, and safety concerns. Morgan developed comprehensive CAPEX engineering and project management documents to support the justification for installing Automated Case Packers for their bagged products. Collaborating closely with the plant operations team, Morgan developed the project scope and justification, including detailed savings calculations, capital and expense schedules, asset write-offs, downtime and installation Gantt charts, as well as equipment selection and procurement. Morgan’s Project Manager presented the projects on behalf of the plant to the senior leadership for CAPEX approval. The project scope focused on installing inspection equipment, automated case packers, labeling equipment, and bag and case conveyors to replace the existing manual packaging lines. The overall timeline was 15 months and included the FAT of equipment, equipment installation, commissioning, qualification, and EHS and operations approval.

Aseptic Pouch Feasibility Assessment

Morgan provided a Packaging Feasibility Assessment and Conceptual Design for a 64-oz aseptic pouch for various fruit puree products. Although the client initially aimed to convert their 49 oz. can to a ~64 oz. aseptic stand-up pouch with a re-closable fitment, their pouch OEM indicated that a 64 oz. aseptic system was not yet available. Morgan’s team aligned with the client on the desired packaging performance (which included an 18-24 month shelf life and 7-14 days refrigerated shelf life once opened) and the client's core requirements such as the number of SKUs, annual volumes, processing parameters, and package specifications for each SKU. Morgan utilized this input to conduct a confidential search for potential aseptic filling systems, pouch manufacturers, and co-manufacturers. The team successfully identified a commercially viable solution, including co-manufacturers that aligned with the client’s processing and scheduling needs. These findings and recommendations were presented in a final report to the client and were used as a critical baseline to select co-manufacturers and packaging formats to meet their operational needs.