Packaging Vendor Transition Roadmap: How to Switch Suppliers Safely

Switching packaging vendors can feel risky, especially if you have upcoming launches or medical device obligations. A structured transition plan reduces the chance of stockouts, quality problems, or regulatory issues.

1. Document Your Current State

Collect current dielines and CAD files
Gather specifications, material callouts, and tolerances
Save inspection reports and quality history
List SKUs, volumes, and delivery patterns

2. Define Transition Objectives

Lower risk or improve quality
Reduce cost or lead time
Add capabilities for upcoming 2026 products
Improve communication and project management

3. Identify and Qualify New Suppliers

Pre-screen factories or partners for your category
Review certifications (ISO, medical device experience, etc.)
Confirm they can support forecasted growth

4. Run Controlled Samples

Request first articles based on your existing designs
Compare print, structure, and dimensional accuracy
Check compatibility with your production and fulfillment flows

5. Overlap Old and New Vendors

Build safety stock where feasible
Phase in new supplier by SKU or region
Monitor early production closely and adjust

Need Help Planning a Vendor Transition?

Influence Packaging helps Bay Area startups and medical device teams manage safe packaging vendor transitions.