Customer Overview
Arbor Teas is a specialty tea company committed to sustainability and environmentally responsible packaging. As a brand serving customers who value both product quality and environmental impact, compostable packaging plays an important role in their business.
However, finding compostable packaging that could withstand the unique challenges of oil-rich tea products proved far more difficult than expected.
What began as a search for a solution to recurring packaging failures ultimately became a successful partnership built on technical expertise, product performance, and trust.
The Challenge
When Arbor Teas first contacted Enviro Flex Pack, they were experiencing significant packaging quality issues with their existing supplier.
Their compostable tea bags were suffering from:
- Internal delamination after being filled with oil-rich teas
- Frequent bag failures and tearing
- Packaging durability concerns that threatened product presentation and shelf life
Because many tea varieties naturally contain essential oils, the packaging needed to withstand prolonged exposure without compromising structural integrity.
The customer was actively searching for a solution but ultimately chose another supplier before moving forward with Enviro Flex Pack.
Staying Connected
Although Arbor Teas did not initially place an order, Enviro Flex Pack maintained contact and periodically checked in over the following year.
During that time, we noticed the company had launched new packaging, suggesting they had moved forward with another supplier.
Rather than continuing with a sales-focused approach, we simply wished them success and expressed our hope that their packaging challenges had been resolved. We also let them know that if problems ever resurfaced, we would be available to help.
That message would eventually become a turning point.
The Packaging Problems Return
In January 2026, Arbor Teas reached back out.
Unfortunately, the new packaging had developed a variety of serious performance issues.
The customer reported:
Internal Delamination
The package layers were separating from one another after product contact.
Corner-Induced Tearing
Sharp bag corners were creating stress points that led to tearing during handling and shipping.
Weak Side Seals
The side seals lacked sufficient strength and durability.
Ink Blocking and Surface Damage
Printed surfaces were sticking together in folded areas, causing tearing and cosmetic damage when bags were opened.
Bag-to-Bag Punctures
Sharp corners from stacked bags were puncturing neighboring packages, creating additional failures during transportation and storage.
After changing suppliers multiple times, Arbor Teas still had not found a packaging solution capable of addressing all of these issues.
Enviro Flex Pack's Technical Assessment
Our team carefully reviewed the customer's concerns and identified several likely causes.
We explained that compostable packaging can present additional challenges when used with oil-rich products, as oils may accelerate degradation or increase the risk of layer separation depending on material construction.
Rather than simply offering another bag, we evaluated each failure point individually.
Delamination Risk
We selected a compostable structure specifically designed to improve resistance to internal layer separation.
Corner-Related Damage
We incorporated rounded corners to eliminate the sharp edges responsible for punctures and tearing.
Seal Integrity
We recommended a structure with stronger seal performance to improve package durability.
Print Performance
Our printing process was designed to prevent ink transfer and blocking issues commonly seen in lower-quality packaging.
Most importantly, we were transparent about the limitations and risks associated with compostable materials while helping the customer find the best possible solution within their sustainability goals.
Real-World Testing Before Production
Despite our recommendation to carefully evaluate performance with their products, Arbor Teas remained committed to using compostable packaging.
To ensure confidence before production, Enviro Flex Pack provided sample bags for real-world testing.
The customer filled the bags with their tea products and monitored performance over several weeks.
After approximately 25 days of testing, Arbor Teas reported:
"We opened the test bags today and I'm happy to report that they are holding up really well! We see some staining on the inside from the oils, but no delamination. And the outside looks really nice."
This was a significant result.
The customer had already worked with multiple suppliers and continued experiencing packaging failures. Yet within only a few weeks of testing, Enviro Flex Pack's samples were already outperforming their current packaging.
When we suggested extending the test period to further validate long-term performance, the customer agreed that a longer test would provide additional certainty but explained that inventory timelines required them to move forward.
Their response highlighted the confidence they had already gained:
"The samples you provided are already performing better than our current packaging regarding delamination."
The Solution
Following the successful testing phase, Arbor Teas moved forward with two custom packaging programs:
Small Format Tea Pouches
- Three-layer compostable structure
- Optimized for product protection and sustainability
Large Format Tea Pouches
- Four-layer compostable structure
- Enhanced durability and structural strength for larger package sizes
Each structure was selected based on the specific performance requirements of the product and package format.
Results
Delamination Problem Significantly Improved
The customer's primary packaging failure showed dramatic improvement during testing, even before long-term validation was completed.
Better Structural Integrity
Rounded corners and stronger package construction helped address several of the tearing and puncture issues experienced with previous suppliers.
Improved Print and Package Appearance
The sample bags maintained a clean, premium appearance without the ink-transfer issues found in the customer's previous packaging.
Successful Transition to Production
Arbor Teas proceeded with custom production after validating the performance of the samples.
Confidence Through Technical Expertise
Rather than simply supplying packaging, Enviro Flex Pack helped the customer understand the relationship between compostable materials, oily products, package design, and long-term performance.
Key Takeaway
Sustainable packaging should not require sacrificing performance.
When Arbor Teas encountered repeated failures from multiple packaging suppliers, Enviro Flex Pack took a different approach—analyzing the root causes, addressing each technical challenge individually, and validating performance through real-world testing before production.
The result was a compostable packaging solution that delivered stronger performance, improved durability, and renewed confidence in the customer's packaging program.
For brands packaging oil-rich products, technical expertise can make the difference between recurring failures and long-term success.
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