Brands of all sizes know that a great package speaks volumes for your brand. The right package attracts buyers, extends shelf life, and even boosts consumer engagement.
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Whether you’re launching a new product or undergoing a package design overhaul, consider using custom resealable pouches to get the most from your packaging.
Every small stop a customer makes either cruising the aisles, at the farmer’s market, or online is your chance to stand out.
Don’t miss the opportunity to grab a customer’s attention with the most effective way there is: packaging that stands out from the pack.
A lot of companies just starting out use those tried-and-true stock bags. You know the ones, they’re plain brown paper bags.
Or the clear plastic ones affixed with labels/stickers for your product’s packaging that lets the customer know you exist, but don’t say much else.
These options certainly do the job of housing and protecting your product when you’re starting out and selling your product locally at community stores, farmer’s markets, etc.
But here’s the thing, stock bags work on a smaller scale, but they, unfortunately, don’t allow you to compete with the big brands on shelves.
So, let’s fix that.
Custom pouches elevate and legitimize your brand. This type of A+ level custom packaging sends a clear message to consumers that what’s inside is a quality product.
With the use of various films and film properties, like matte, gloss, or clear, you can take advantage of how these all best highlight your product and differentiate your brand.
For example, a clear window allows you to show off your product to curious shoppers, while matte film offers a tactile consumer experience. The move from stock bags to custom pouches reflects your brand’s growth and readiness to reach for a wider consumer base.
Picking a look for how you wish to represent the brand is an easy but effective way to let a customer know exactly what you do, but also that you’re offering a quality product.
One of the notable benefits of custom resealable pouch packaging is that they can provide what a stock bag and sticker can’t: all over design. You’re no longer limited by the size of the sticker. You can use your brand colors, design, and messaging on every inch of the pouch (even on the bottom of the gusset!) for 360° branding. You’re also in control when it comes to to the size and shape of the pouch, as well as which user features to include – the design is all up to you.
And according to Nielsen, package design is one of the most effective marketing levers, working hard to capture attention and ultimately, drive purchase. Nielsen reports that 64% of consumers try a new product because the package catches their eye, and 41% will continue to purchase a product because they prefer its packaging.
Consumers love resealable packaging. It’s actually one of the top three packaging attributes of flexible packaging rated by consumers, according to the Flexible Packaging Association.
Moisture and oxygen threaten the freshness of many food items, and when present can cause the product to become stale, or even moldy.
Flexible packaging that features a reseal closure, like a zipper allows users to securely close the pouch, keeping oxygen out and freshness in.
And consumers love that the food item maintains its freshness over several uses and also allows them to take the package on the go, without the risk of the resealable product bags spilling open.
For products that you wouldn’t want to get into the hands of children, such as nutritional supplements, herbal medicines, or lawn and garden supplies, there is the option to have tamper-proof resealable bags.
These child-resistant bags are easy for adults to open and reseal, but hard for children to find their way into.
Resealable pouch packaging has many benefits and these are just some of them that can affect how your brand attacks the market on a consistent basis.
In addition, flexible packaging helps to extend your food product’s shelf life using the use of high-quality barrier film that works to efficiently block oxygen transmission, water vapor, and light from contacting your product. The high barrier film and reseal closure in custom pouches work together to keep your product fresh on store and pantry shelves longer.
Ordering digitally printed resealable bags helps you to compete with big brands, regardless of the size of your business, by giving you the tools to truly customize your packaging. Digital printing allows you to create incredible graphics with photo-like quality while ordering custom pouches gives you the opportunity for differentiation and customization.
Digital pouch printing also allows you to print multiple SKUs within one order, meaning that you can add new flavors, ingredients, and designs with ease. Interested in breaking into a new market? With digitally printed custom pouches, you can modify your packaging’s messaging with ease so your brand can launch new products into the market quicker.
Plus, digitally printing with a custom packaging company allows for experimentation – no matter the company’s size. That’s a big win for small company’s A/B testing what works and what doesn’t.
When the markets are as competitive as they are right now, getting the edge is everything, even if the red resealable pouch outsells the blue resealable pouch. Because there are no plate fees, a change is made with a file upload at no additional cost, which is a game-changer for those on a budget.
Ready to learn more about how digitally printed custom resealable pouches are the solution for your brand?
The resealable pouch is the class move that is time-tested and consumers love it. So what not create custom resealable bag that will get products moving and registers ringing?
Whether you’re launching a new product or going through a package design overhaul, we have flexible packaging solutions that can help build your brand. Give us a call today, or click here to get a free quote.
We’re ready to help your company rise to the occasion and dominate the market. We’ve got the bags; you’ve got the brains.
Are you looking for something to elevate your product and its packaging to the next level? What if we told you that there is a type of packaging that elevates your brand’s presence on the shelves while also being functional for your products and sustainable for the environment? The packaging we’re referring to is custom pouches.
With the rise in demand for packaged food, businesses are increasingly adopting flexible packaging for their products that cater to cost-effectiveness, sustainability and aesthetic appeal. Pouches are just one type of flexible packaging that’s seen an increase in popularity in recent years, and for good reason.
Pouches are versatile for many industries, such as food, beverage, medical, pharmaceutical, cosmetics, and personal care, with MarketsandMarkets projecting stand-up pouches to dominate the pouch market from to . Stand up pouches for food and drink, in particular, have seen a spike in demand due to their inherent synergies with the products and abundant benefits to the food industry. So, in this guide, we will cover everything you need to know before beginning your pouch packaging project!
The Flexible Packaging Association states that flexible packaging is one of the fastest-growing packaging industry sectors. Additionally, according to a industry report by GlobalData, businesses that switched to stand-up pouches reported a 25% increase in shelf impact and a 30% reduction in packaging costs.
Flexible packaging and, by extension, pouches packaging add value to food and non-food products by combining the best protective qualities of plastic, film, paper, and aluminum foil while using the least amount of materials. Pouches offer:
While the benefits mentioned above can extend to both custom and premade pouches, custom-made pouches offer so much more than stock pouches. Though premade pouches are lower in cost, customization is almost non-existent, a significant disadvantage to your brand in today’s market.
On the other hand, custom stand up pouches are designed from scratch to fit your product and branding requirements. The possibilities are endless, and at PakFactory, you can customize everything from the type of pouch to the materials, coating, layers and features. By developing a unique design that’s pleasing to the eye, convenient, and functional for customers, you are creating a positive image of your brand that will help distinguish you from the competition!
So, with custom pouches in mind, the first thing you can decide is the type of pouch you want for your product. Different pouches have their own set of benefits, but the ability to choose the one that best fits your product is another plus over premade pouches.
Stand up pouch bags are ideal for storing and displaying foods or other retail products. They are one of the main go-to options for flexible packaging and are available in various sub-styles.
The block bottom bag, or flat bottom bag, is a pouch with a flat rectangular base that is sometimes gusseted on the sides, allowing it to stand upright. This pouch offers the maximum balance of stability and presence for your product as it can stand upright on the shelf, has good volume and space for heavier products and features 360 degrees of surface area for custom printing.
Block bottom bags are excellent for products such as coffee, pet food, spices, sweets, frozen foods, nutritional products, household chemicals and high-density products.
Bottom gusset bags are a type of stand-up pouch with a rounded gusset bottom that allows the bag to stand independently without support. They are stronger and hold more weight than block bottom pouches. They are also generally larger than side gusset pouches, allowing more products to be packaged. This pouch type is flexible and suitable for many products, such as snacks, candy, coffee, baking powder, custards, liquids, hygiene products, and medical products.
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The three main types of bottom gusset pouches available to you include;
The side gusset is the last sub-style of stand up pouches. As the name suggests, side gusset pouches feature gusseted sides and two flat panels on the front and back, making this style less box-shaped. Side gusset bags take up less space on the shelf but can still hold a good amount of product. Still, their smaller package size makes them more cost-effective, less wasteful, and perfect for storage.
Side gusset bags are popular for snacks, dry ingredients, frozen food, coffee and tea.
A flat pouch, or lay-flat pouch, is a style of flexible pouch packaging that is the most economical out of the other options we will cover in this guide. As the name suggests, lay-flat pouches are designed to lay on the shelf but still offer stability and a large printable surface for customization.
The three main styles available for flat pouches include;
The pillow pouch packaging style is the most common type of flexible packaging. When filled, the pouch expands in the middle and flattens out at the top and bottom seals to resemble a pillow. Pillow pouches are cost-effective, use little space during storage and transport, allow for complete customization on the package’s front and back, and are ideal for single-serve products, snacks, frozen foods, and meal kits.
Pillow pouches also have other optional features, such as press-to-close zippers, hanger holes, product display windows, and tear notches.
Three-sided sealed bags are similar to their four-sided cousin but are sealed on three sides and folded on one. The fold is generally featured on the bottom of the package to allow flexibility and the product to settle at the bottom of the bag, making this pouch ideal for ground products, coffee, snacks, spices, pet food, and produce.
A three-side sealed bag offers the same optional features as the other flat pouch styles while providing more bag volume than the four-side sealed bag and maintaining cost-effectiveness, efficient storage and transportation and good package uniformity for cartoning.
As the name suggests, a four-sided sealed bag is sealed on all sides to provide the best protection against leakage while still being customizable on the front and back panels. Unlike a pillow bag, this flat pouch cannot flex and expand as much, but it is a popular choice for liquid, medical, or sample products.
Four-sided sealed bags are also cost-effective, efficient to store and transport, and offer the same optional features as pillow bags.
Roll stock is a printed and laminated film on a roll that is then used with Form, Fill, Seal (FFS) machinery to form a package, fill it with a product, and seal it. This package option allows brands to create pouches using their own equipment, allowing for high speed and output over long runs.
Roll stock is perfect for smaller items such as nutrition bars, packaged snacks, single-serve samples and stick packs.
Custom shaped pouches offer the ultimate form of customization for your flexible packaging endeavors. If none of the above styles fit your brand’s identity, consider creating a shape that best suits you! Whether you are looking for a standing or flat pouch, you can always customize the bag to suit your desire. From the shape, size and openings to other optional features, a custom shaped pouch is guaranteed to elevate your packaging further.
After deciding on the type of flexible pouch that fits your product, you need to consider the materials you want to use to create it. How pouches are made plays an equally crucial role in your packaging project as the type of pouch you choose, so it is worth considering all the options when making your decision. Some typical pouch materials used include plastic, metal foil, paper, and bioplastics.
Plastic is an excellent barrier against contaminants like oxygen, moisture, dust and UV light. It helps maintain your product’s freshness and has good material qualities like rigidity, stability, flexibility, tensile strength and transparency.
However, plastic has a low melting point and cannot withstand high temperatures. It has a shorter life cycle than containers like glass or metal and is very environmentally harmful, with challenges related to waste, disposal, and recycling.
Plastic materials for pouches are typically made of;
Metal foil provides maximum protection for your product against moisture, light, aromas, and oxygen, extending its shelf life. Foil packaging is durable, resistant to punctures and tears, and can withstand various temperatures.
However, it must be noted that foil still cannot be microwaved and is also harmful to the environment when improperly disposed of. Like plastic, it is non-biodegradable and can take hundreds of years to break down. In addition, foil is more expensive than other materials, such as paper and plastic.
Paper materials are available in natural brown or white kraft. Unlike plastic and foil, kraft stand up pouches are naturally compostable while offering excellent barrier properties that protect a product from spills, pests, UV rays, oxygen, and moisture. Kraft paper also provides a high tensile strength, making the pouch resistant to punctures.
However, though kraft paper offers moisture protection, it still has poor water resistance and strength compared to other materials.
Bioplastics are an environmental alternative to traditional plastics, offering similar protective properties while being less environmentally impactful. Made from plants or other biological materials like polylactic acid (PLA), bioplastic reduces carbon emissions by being biodegradable, breaking down naturally without releasing harmful chemicals. Bioplastics are also resealable, allowing the use of recyclable pouches to further contribute to a sustainable initiative.
However, though bioplastics seem to have all the benefits of plastic without the negatives, this is untrue. Bioplastics generally cost more—though their recyclability somewhat counteracts this—and sometimes have a shorter lifespan than traditional plastics, depending on the type of material used. Also, though bioplastics are biodegradable, they require special facilities and proper disposal to reduce pollution effectively.
We briefly mentioned the optional customization earlier in this guide, but more than a brief mention is needed to show you the breadth of what you can do with a custom pouch. Pouches feature many customizable options, such as various fitments, closures, merchandising features, layers, and shapes.
The first type of customization we will look at are the fitments and closures. These customizations contribute to the longevity of your product by determining how the pouch dispenses your product and whether it can be closed again. Popular options include;
These customization options help display your pouch on store shelves and attract potential customers with convenient additions to your packaging. Options include;
Barrier and coating layers come in direct contact with the product and protect the pouch and its contents against contaminants by providing crucial barrier properties. These customizations improve packaging integrity and structure while increasing shelf life and preventing food waste. Barrier properties for stand-up and flat barrier pouches include;
Typical coating materials to achieve the above barrier properties include aluminum foil, EVOH resin, transparent film, nylon, polyethylene terephthalate (PET), polyethylene (PE), and breathable or permeable barriers.
Pouches typically have multiple layers of material structure, all of which can be customized for different functions to market, protect, and preserve a product. Layers include;
With your packaging customized to your liking, it’s time to consider one of the most crucial factors in your pouch packaging endeavor: how to fill stand-up pouches.
Not only do different treatment and packaging techniques contribute to your product’s ability to maintain taste and freshness while having an optimal shelf life, but they are also crucial to meeting safety, compliance, and quality standards established by regulatory bodies like the FDA.
Standards for product sterility, sterile zones in the manufacturing process, packaging systems, materials and more are all requirements, so carefully considering your treatment and filling methods and ensuring they meet FDA or other regulatory body standards is essential. Common filling and treatment methods include;
The most basic and generally low-cost method of filling involves using a scoop or similar tool to fill a pouch by hand. The bag is then manually sealed using impulse heat-sealing or direct heat-sealing equipment. Manual filling allows greater control over quantity and quality but may only be suitable for small-scale operations or starting businesses, as this is far from ideal at larger scales.
Aseptic packaging is the typical method used in the food and pharmaceutical industry. The product is sterilized through quick exposure to high heat in a technique known as flash pasteurization and then rapidly cooled to room temperature. The product is then filled into sterilized pouches and sealed in a sterile environment, enabling the packaged contents to last up to 18 months.
Ideal applications for aseptic filling include liquid pouch packaging for milk or high-acid products such as juices in glass, aluminum or PET containers.
The retort-filling method involves filling a package with a non-sterile product and sealing it in a non-sterile, retort-able flexible pouch with heat-resistant plastic layers that can withstand high temperatures with or without aluminum foil so the product can be thermo-processed. The retort pouches are then loaded into a retort pressure chamber and sterilized with heated pressurized steam.
Retort pouch packaging is ideal for foods with a pH level greater than or equal to 4.5, such as chicken breasts, chili, ham, and tuna.
The hot-filling process involves sterilizing a product through high heat before filling it into a non-sterile container and immediately cooling it to preserve taste and quality. Opposite to retort packaging, hot-filling is suitable for foods with a pH lower than 4.5 and is also cost-effective for various liquids, including soft drinks, non-carbonated beverages, juices, water, and teas.
The design and print are the final things to consider when planning your pouch project. Depending on the purpose, budget, and type of finish you are looking for, one technique might better suit your needs than the others.
But before we discuss the various techniques available to you, it is important to note that color matching with packages involving two or more components of different materials may be difficult regardless of your chosen printing technique. So, with this in mind, let’s look at the various other pros and cons each printing technique offers.
Flexography is the most commonly used technique for pouch printing and works very well on pouches made of kraft material. It involves rolling the pouch through a printing press and then pulling it into several printing units. Flexography is best for larger runs, as it has high setup costs but has the lowest cost per unit among the other printing options. It offers minimal coloring and lower print qualities unsuitable for photo images but excellent for simple designs and a quick turnaround time.
This printing method works well on a wide selection of materials and involves engraving the image design on multiple color plates and transferring it onto the pouch. Like flexography, rotogravure is best for larger runs with a high setup cost and a lower cost per unit. However, unlike flexography, rotogravure offers crisper colors and exceptional image quality.
The digital printing method involves printing digital-based images directly onto the pouch. This technique is best for smaller runs and dynamic content like special promotions and serialization as it has no setup costs but a higher price per unit. Digital printing offers the fastest turn-around time while having a high print quality and can be used on most materials.
Although this guide contains many factors to consider and may be overwhelming, they are all equally essential to a successful custom pouch project. However, you do not have to work alone. Whether you are looking for more help, are ready to find a pouch packaging manufacturer or partner, or want to jump right in and order custom pouches, PakFactory is the choice for you.
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