Quality and Regulatory Systems
New Wave Converting, Inc. has earned a reputation for producing high-quality flexible packaging. We continually invest in our state-of-the-art manufacturing equipment as well as our highly skilled machine operators. We uphold our manufacturing of flexible packaging materials under strict GMP conditions. Our products adhere to stringent quality standards to meet the needs of our FDA regulated customers. By maintaining a GMP based manufacturing environment, our robust quality systems implement a comprehensive HACCP program, supplier and material management, with internal and external auditing.
New Wave Converting, Inc. holds SQF (Safety Quality Foods) through SCS Global Services certification for manufacturing of flexible film and pouches. Ensuring product safety, integrity, legality, quality, and the operational controls in the food packaging industry.
SQF certification is a food safety standard recognized by GFSI (Global Food Safety Initiative). GFSI has approved SQF as one of the benchmarked schemes that meet their stringent requirements for food safety. This recognition provides a meticulous framework to follow during the production of safe authentic packaging material which helps to better manage product quality to meet customers’ requirements. All while maintaining legal compliance for food packaging.
Our quality systems are rooted in ISO principles and FDA GMP requirements, and specific elements include (but are not limited to) the programs and policies listed
- Supplier Qualifications
- Raw Material Qualifications
- Independent Release of Materials
- Incoming Materials Management
- Document Control
- Letters of Certification
- Certificates of Analysis
- Good Manufacturing Practices and Requirements
- Preventative Maintenance Program
- Pest and Insect Control
- Scales and Calibration
- Food and Beverage Policies
- Process Water Verification
- Glass and Brittle Plastic Policies
- Product Recall and Mock Recall
- Process Risk Review
- Supplier and Customer Audits
- Internal and Third-Party Audits
- Non-conforming Materials
- Product Holds
- Complaint Management
- Corrective and Preventative Action
- Customer Change Notifications
Rigorous Quality Test On Our Products Include:
- Product Compatibility Testing – testing to determine which flexible packaging laminations are most resistant to chemical degradation or physical change caused from interaction with the product.
- Compression Testing – subjecting pouches to various air pressure forces for varying lengths of time.
- Interlayer Adhesion Testing – verifying that the layers of the packaging film structure meet the required bond level for each application.
- Seal Testing – testing for fusion seals that bond the plastics in the flexible packaging material together on a molecular level, the same way that the plastics in a rigid container are formed.
- Puncture Resistance Testing – Using ASTM testing standards, analyzing how much pressure is required to puncture the flexible packaging material.
- Tensile Testing – sealing the flexible packaging film to itself and evaluating the amount of force required for the seal to break.
- Vacuum Testing – submitting pouches to the equivalent of 1 atmosphere of external vacuum pressure to ensure that they are hermetically sealed.
- Burst Testing – exposing pouches to internal pressure until they burst to verify the strength of the seals.
- Drop Testing – evaluating the height from which the pouch can be dropped without failing.
Package Engineering Expertise
Reverse Engineering
Assisting with the process of selecting a proper flexible packaging structure, our packaging engineers reverse engineer existing flexible packaging from the marketplace to help you determine what materials are best used for existing products. Also referred to as “material breakdown analysis”. (Infrared Breakdown)
Package Engineering
Our packaging engineers are among some of the industry’s top flexible packaging experts, while providing personalized, one-on-one technical support. Our wide variety of complimentary technical services are provided for our customers to help determine structures based on your product’s unique formulation, distribution process, usage characteristics, project life cycle, and filling equipment.
Product and Packaging Compatibility Testing
This testing determines how your product interacts with various flexible packaging structures and will help with identifying adverse effects that a product has on packaging materials, such as chemical degradation or delamination. This testing is an invaluable tool when selecting flexible packaging materials that will perform over time.
Pouch Sizing
Our suggestion of pouch dimensions are based on the product type, volume, and developed pouch mockups or prototypes in various configurations.
Package Design and Prototypes
Our packaging engineers provide comprehensive package design services, helping you bring your package from conception to engineering to production. Collaborating and brainstorming with you to ensure your packaging meets the goals of all stakeholders. Our packaging engineers can create innovative packaging or stand-up pouch prototypes. Including printed with your own graphics incorporating other value-added features that provide convenience and shelf impact.
On Site Technical Assistance
Our packaging and process engineers are readily available to travel to your location and troubleshoot issues or provide insights when running our flexible packaging films on your filling machinery.
Pouch Testing
Our packaging engineers will subject your packaging to various types of testing:
- Product/ Package compatibility testing
- Compression testing
- Interlayer adhesion testing
- Seal testing
- Puncture resistance testing
- Tensile testing
- Burst testing
Custom Slitting and Film Profile
Slitting capabilities:
- Ability to rewind rolls from 3″ to 32″ in diameter
- High-speed, precision slitting in widths from 1.5″ up to 60″
- Wide range of slicing options/techniques available
- Ability to perform barcode quality scans and inline print repeat monitoring
- Custom labeling and packaging
NEW WAVE'S FILMS ARE KNOWN FOR:
- Running at faster speeds
- Performing consistently on form, fill, and seal lines
- Improving efficiency and reducing downtime
- Providing consistency from roll to roll
- Eliminating the need for constant adjustments on filling lines
- Running well down to the roll core to reduce material scrap waste
Expertise in adhesive laminating allows New Wave Converting, Inc. to provide a wide range of sophisticated packaging film laminations.
