As a flexible packaging manufacturer, we often see brands prioritize color accuracy or print resolution in their quality control (QC). While aesthetics are vital for shelf appeal, we believe that drop testing should come first. specifically for flat bottom bags.
In this post, we’ll explore why drop testing is the non-negotiable first step in tea packaging QC, how it protects your product’s integrity, and why our flexible manufacturing process ensures your bags can take a hit and keep your tea fresh.
1.What is Drop Testing?
At its core, drop testing is a controlled simulation of the physical abuse a package will endure during the supply chain.
①We take a finished, filled flat bottom bag.
②Drop it from varying heights (typically adhering to ASTM or ISTA standards) onto a rigid surface.
2.Validating Seal Integrity Under Stress
The sealing process for flat bottom bags is more complex than standard pouches.
The goal isn’t just to see if the bag explodes. We are looking for:
- Seal Strength: Do the bag was broken?
- Micro-leaks: Does the impact force air through a weak point in the zipper or gusset?
- Puncture Resistance: Do the tea stems pierce the inner layer upon impact?
Drop testing exposes seal weaknesses immediately. A seal that looks perfect under visual inspection might fail catastrophically when subjected to impact stress. Early drop testing allows you to refine sealing parameters before production scale-up.
The video below demonstrates the drop test conducted on the flat bottom bag.
3.The Technical Advantages of Early Drop Testing
Identifying Material Limitations Before Production
Different laminate structures respond differently to impact stress. A flat bottom tea bag might use:
- PET/AL/LDPE for maximum barrier protection
- PET/VMPET/PE for cost-effective moisture resistance
- Recyclable mono-materials like MDOPE/BOPE/PE for sustainability
- Compostable films for eco-conscious brands
Each material combination has different puncture resistance, tensile strength, and impact absorption properties. Drop testing early in the development phase reveals whether your chosen materials can withstand distribution stress, allowing you to adjust the laminate structure before committing to inventory.
4.Cost Savings Through Preventive Testing
a.Preventing Production Waste
Imagine producing 50,000 flat bottom tea bags, only to discover during filling trials that they fail drop tests at your target fill weight. The cost implications are staggering:
- Wasted film materials
- Lost production time
- Delayed market launch
- Emergency redesign expenses
- Potential penalties for late delivery to retailers
Early drop testing costs a fraction of this waste. A few hundred test bags can prevent hundreds of thousands of dollars in losses.
b.Reducing Customer Complaints and Returns
Tea brands face intense competition. A single bad experience—receiving a damaged package with spilled tea—can drive customers to competitors permanently. In the age of social media, one customer’s complaint can reach thousands of potential buyers.
Drop testing first ensures that by the time your tea packaging reaches consumers, it has already proven its durability under the most demanding conditions they’re likely to encounter.
5.How Tongli Packaging Prioritizes Drop Testing for Tea Brands
At our Qingdao facility, we’ve implemented drop testing as the cornerstone of our quality control process for flat bottom tea bags. Our approach includes:
①Pre-Production Testing: Before mass production begins, we conduct extensive drop tests on prototype bags at various fill weights and orientations.
②Material Validation: We test different laminate structures to identify the optimal balance between barrier protection, sustainability, and impact resistance.
③Seal Optimization: Our sealing parameters are refined based on drop test performance, ensuring corner seals and bottom panels remain intact under stress.
6.Conclusion: Drop Testing Is Risk Management
For tea brands investing in high-quality flat bottom bags, drop testing isn’t just another quality check,it’s essential risk management. By prioritizing drop testing first, you:
- Protect your product investment
- Prevent costly production failures
- Build consumer and retailer confidence
Ready to ensure your tea packaging can withstand the rigors of global distribution? Contact our team to discuss drop testing protocols tailored to your specific flat bottom bag requirements. Let’s build packaging that protects your premium tea every step of the journey.