Lollipop Packaging Commercialisation

Overview

Bringing a new confectionery product to market requires precision control over moisture sensitivity, machine-runnability on high-speed lines, child-friendly opening ergonomics, and vibrant retail shelf appeal.

This project encompassed the end-to-end development of the primary barrier twist-wrap and secondary pouch/carton packaging for a new confectionery launch within Wipro Consumer Care.

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Technical Considerations & Barrier Requirements

• Hygroscopic Sensitivity: High sugar-confectionery absorbs ambient moisture rapidly in tropical humid climates, leading to stickiness, graining, and color degradation if water vapor transmission rates (WVTR) are inadequate.
• High-Speed Machine Runnability: High packaging line speeds (over 300 units/min) demand consistent coefficient of friction (COF), static dissipation, and thermal dead-fold retention.
• Food Safety Compliance: All raw materials, printing inks, and adhesives had to strictly adhere to Food Contact Materials standards under FSSAI regulations.

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Development Milestones

1. Substrate Specification & Barrier Engineering

• Evaluated high-barrier metallized cast polypropylene (CPP) vs. bi-axially oriented polypropylene (BOPP) laminates to balance optimal moisture barrier (WVTR < 1.0 g/m²/day) with cost efficiency.
• Verified seal integrity and cold-seal adhesive release profiles to prevent flavor contamination.

2. AutoCAD Key Line Drawings (KLD) & Tooling

• Drafted precise 2D KLDs for wrapper cut-off lengths, eye-mark positioning for optical photo-sensors, and secondary hanging-hole pouches.
• Built comprehensive Bills of Materials (BOM) and technical packaging specifications approved across factory production sites.

3. Factory Line Trials & Transit Validation

• Executed pilot and full-scale factory line trials, tuning seal jaw temperatures, wrapper tensioners, and twist-head grippers.
• Validated real-time ambient and accelerated shelf-life stability tests (38°C / 90% RH) over a 6-month evaluation period.

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Commercial Outcome

• On-Time Nationwide Launch: Commercialised on schedule with zero line downtime during commercial commissioning.
• Extended Shelf-Life: Maintained product crispness and flavor profile across peak monsoon conditions without moisture ingress.
• Robust Documentation: Handed over standardized, audit-ready Packaging Material Specifications (PMS) to QA and plant operations teams.