That takes 60 to 90 minutes, and when the line restarts, it takes additional time to get up to speed. Changeover costs are usually in dollars or tens of dollars per minute. It's significant, and it's real money that drops from the product's margin. This scenario is repeated in all kinds of products. Yet, it can be avoided if marketers and package designers communicate with operating people.
Several considerations go into the design of a package.
Generally they can be divided into protection and aesthetics. The problems from an operations standpoint tend to come from aesthetic design considerations. Marketing people want a package that is pleasing to the customer. In order to stand out from the crowd the package needs to be distinctive in some way. This is a fine goal and we on the operations side fully support it.