As production volumes and SKU counts increased, the customer began facing inconsistent sealing performance after retorting, packaging variability between batches, and frequent machine adjustments. These issues led to higher material waste, rework, and reduced line efficiency. EPAK optimized the packaging structure, heat-seal performance, dimensional consistency, and quality-control standards based on the customer’s filling process, retort conditions, and existing packaging equipment. The project helped the customer move beyond packaging unit cost and focus on the total cost of producing a qualified finished pack. More consistent packaging performance also provided a stronger foundation for production scale-up and future product launches.