Packaging Redesign — Remove Zip-Seal, Add Twist-Tie
Overview
Doodla Farms is redesigning its popcorn bags to eliminate a faulty zip-seal closure that has been generating customer complaints. The new design will use a longer bag with enough material at the top to allow a twist-tie closure instead.
This work is expected to be funded in part by a $300k state popcorn marketing grant received by Doodla Farms.
Problem
The current bags have two related issues:
- Faulty zip-seal: The zip-seal closure is breaking and generating complaints.
- Overfilled bags: Bags are packed so full that once opened and partially used, there is not enough slack material at the top to re-close them — even with the existing zip-seal, let alone without it.
The combination means customers who remove even a small amount of product have no practical way to reseal the bag.
Solution
Replace the current bags with a longer bag design that:
- Removes the zip-seal entirely (eliminating the failure point)
- Adds extra material at the top so the bag can be scrunched and secured with a twist-tie
Mark noted this should resolve approximately 99% of packaging complaints.
Status
- Decision made: Yes — discussed and agreed during the 2025-11-18 internal team call
- Implementation: Pending — Lucy (Doodla Farms) is coordinating with Jen on what the new bags will look like
- Funding: To be covered under the state popcorn marketing grant