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Copacker Insight: Navigating The Aseptic Copacker Realm: Why is it so hard?

Updated: Apr 30

Today, I wanted to share some thoughts about the challenges of finding an aseptic copacker. For many businesses in the food and beverage industry, the need for aseptic packaging is a crucial aspect of ensuring the quality and safety of their products. Aseptic packaging involves sterilizing both the packaging material and the product separately, then filling and sealing the product in the sterile package in a sterile environment.


One of the main difficulties in finding an aseptic copacker is the scarcity of facilities equipped for aseptic packaging. Aseptic packaging requires specialized machinery and strict adherence to aseptic processing procedures. These facilities must uphold high standards of cleanliness, employ skilled staff, and invest in sophisticated aseptic technology. As a result, there are relatively few copackers with the capabilities and expertise to provide aseptic packaging services.


A recent increase in the type of packaging,



in addition to the hiring stresses caused by COVID over the past few years, has lead to decreased line time availability. Many Copackers are increasing their minimum run requirements, focusing on their larger client brands and ignoring startups who aren't funded for major initial production.


Moreover, identifying a copacker that aligns with your specific product requirements and business goals can be another hurdle. Different copackers may specialize in certain types of products, packaging formats, or production volumes. Finding a copacker that can accommodate your unique needs while maintaining the aseptic standards can be a complex task.


Another challenge is establishing a strong and reliable partnership with an aseptic copacker. Trust and communication are paramount in such a relationship, especially when dealing with the intricacies of aseptic packaging. It's important to ensure that the copacker not only has the technical capabilities but also shares your commitment to quality, safety, and customer satisfaction.


In some cases, companies may also face obstacles related to geographical proximity. The ideal aseptic copacker for a business may be located a significant distance away, presenting logistical complexities and potentially impacting transportation costs and lead times.


Despite these challenges, it’s important for businesses to persevere in their search for an aseptic copacker. Aseptic packaging can offer numerous benefits, including extended shelf life, preservation of product quality, and the ability to package a wide range of products, from beverages and dairy to soups and sauces. With the right copacker, businesses can expand their product offerings, enter new markets, and meet the demands of increasingly health-conscious consumers.


To navigate the process of finding an aseptic copacker, businesses should consider engaging in thorough research, reaching out to industry contacts for recommendations, and conducting site visits to assess potential co-packing partners firsthand. It's also advisable to clearly outline your expectations, specifications, and key performance indicators when engaging with copackers, ensuring that both parties are aligned from the outset.


Furthermore, fostering open and transparent communication with potential copackers is essential. This includes discussing quality control measures, production schedules, and contingency plans to address any unforeseen challenges that may arise during the co-packing process.


Ultimately, finding the right aseptic copacker is an investment in the future of your business. By partnering with a copacker that excels in aseptic packaging, you can elevate the quality and safety of your products while enhancing your operational efficiency and market competitiveness.



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