---
title: Old World Popcorn Packaging Solution
type: article
created: '2025-12-05'
updated: '2025-12-05'
source_docs:
- raw/2025-12-05-weekly-call-w-karly-106748766.md
tags:
- doodlers
- old-world-popcorn
- packaging
- amazon
- operations
layer: 2
client_source: Doudlah Farms
industry_context: food-beverage
transferable: false
---

# Old World Popcorn Packaging Solution

## Overview

Doodlers identified a recurring packaging defect with Old World Popcorn bags that was generating negative Amazon reviews. The root cause was traced to zipper-style bag closures failing during shipping. The team has moved to a self-packing model using longer, heat-sealed bags without zippers to resolve the issue.

## Problem

Frequent bag failures on Old World Popcorn products were driving negative Amazon reviews. Nearly all complaints centered on bags breaking open in transit — a frustrating but non-safety-critical issue (popcorn doesn't spoil). Left unaddressed, the review damage posed a risk to organic rankings and conversion rates on the Amazon listing.

The previous workflow sent product to a third-party packer (TS), which added cost and used bags with zipper closures that were prone to failure.

## Solution

Doodlers will self-pack Old World Popcorn going forward using a new bag format:

- **No zipper closures** — eliminates the primary failure point
- **Longer bags** — provides additional airspace at the top after sealing
- **Heat-sealed closure** — more reliable seal than zipper; customers can cut open and use a twist-tie to reseal

This change trades packing speed (they lack TS's machinery) for cost savings and quality control.

## Impact & Decisions

| Item | Decision |
|---|---|
| Amazon imagery update | **Not required** — bag appearance is close enough to existing photos |
| Packing location | Doodlers self-pack (no longer sent to TS) |
| Cost | Saves money vs. third-party packing |
| Expected outcome | Fewer defect complaints; improved Amazon review trajectory |

## Context

This change was discussed during the [[meetings/2025-12-05-weekly-call-karly|2025-12-05 Weekly Call]] following Mark's in-person visit to the Doodlers farm. The packaging issue was flagged as a meaningful drag on the Old World Popcorn Amazon listing's review score.

Jason (Doodlers' primary packing and farm operations contact) will handle the self-packing. Note that Jason is also responsible for combining crops, so packing capacity may be constrained during harvest periods — see [[clients/current/doudlah-farms/inventory-and-fulfillment-notes|Inventory & Fulfillment Notes]] for related operational considerations.

## Related

- [[clients/current/doudlah-farms/_index|Doodlers / Doudlah Farms]]
- [[clients/current/doudlah-farms/amazon-strategy|Amazon Strategy]]
- [[clients/current/doudlah-farms/popcorn-project-proposal|Popcorn Project Proposal]]