Flexible packages have quickly gained popularity in the packaging industry for being a versatile option to meet the diverse needs in many sectors. In fact, this type of packaging is the second largest segment in the United States, with 19% of the $177 billion U.S. packaging market. Not only does this statistic showcase the substantial market presence of flexible packaging, but it also signifies its growing importance in the industry’s future.
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The adaptability to different product types, sizes, and use cases has all contributed to this growing trend that is even more significant in the food, pharmaceutical, and personal care industries. Due to the convenience of usage, storage, extended shelf life and sustainability, flexible packaging solutions have greatly benefited these industries by providing a versatile option preferred by both businesses and consumers.
In fact, a study by Harris Poll found that 71% of respondents expressed an apparent inclination toward flexible packaging over rigid box counterparts. Of that percentage, 79% were knowledgeable about the packaging alternative and were willing to pay up to 14% more for this convenient and hygienic option.
So with the rapidly growing market share and business and consumer preference in mind, it is evident that this packaging solution will continue solidifying its position as a superior option across many industries.
Source: PakFactory
That being said, if you are considering using a flexible packaging solution for your product, you’ve come to the right place! In this article, we will cover everything you need to know about this excellent packaging option to ensure you have all the necessary knowledge to make this critical decision.
Before deep diving into the many small details that make this packaging option great, it is essential to establish a broader, foundational knowledge to build from. So the first question to always ask is, what exactly is it?
As the name suggests, flexible packaging is a versatile solution made from pliable packaging materials like plastics, paper, films, foils or a combination of all of them. It is any type of packaging capable of changing shape when filled or used, making it a preferred choice for businesses and consumers with its ability to remain lightweight, cost-effective, reduce carbon footprint, extend product shelf life, and take on endless customization.
Compared to traditional packaging types like rigid boxes, flexible packaging is more lightweight and cost-effective. The films and barriers that produce the pliable materials require fewer resources and energy to manufacture while offering a more cost-effective approach to shipping, warehousing, and logistics. Businesses gain the opportunity to save across the entire supply chain while maintaining a high-quality standard, but the benefits don’t end here.
The fewer resources and energy requirements to manufacture saves money and cuts the quantities of greenhouse gases produced compared to traditional packaging. Even during disposal, the efficient use of materials results in less overall waste sent to landfills, minimizing the negative environmental impact of this packaging option and making it an excellent step toward sustainability and a reduced carbon footprint.
Source: PakFactory
Flexible packaging solutions even offer an extended shelf life and increased protection against contaminants. According to ePac Flexibles, this packaging option creates a barrier against oxygen, moisture, light, and microorganisms, which can cause oxidation, spoilage, discoloration, and contamination. This increased protection benefits the product’s shelf life and reduces the risk of product waste created from spoilage.
Finally, endless customization and options for branding are available. The possibilities are truly limitless, from choosing vibrant colors and captivating graphics, incorporating your logo and brand messaging, or selecting the type of package you want with a wide range of options, such as spouted, flat, or stand-up pouch packages. By leveraging these customization options, you can create packaging that protects your products and is a powerful marketing tool, leaving a lasting impression on consumers.
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Now with all the benefits of flexible packaging fresh in your mind, are you convinced to use this packaging solution for your products? If so, let’s look closely into the key considerations before beginning your planning.
Designing effective and successful packaging requires careful consideration of several vital factors. Packaging is the first point of contact between your product and the consumer, so creating a design that captures attention and communicates your brand’s value is crucial. Elements such as color, typography, and graphics are integral to conveying your desired message and attracting the target audience.
Source: PakFactory
Understanding your product’s requirements is also important for selecting the appropriate packaging materials and formats. Product freshness, shelf life, and transportation considerations are all crucial factors you must consider but do not exclude sustainability. Incorporating sustainability and eco-friendly practices are becoming increasingly important in today’s market as more consumers seek environmentally conscious businesses. And though many crucial factors like those mentioned above require careful consideration, you don’t have to do it alone.
Consulting packaging design and manufacturing experts is highly recommended, as they possess the expertise and industry knowledge to help you make informed decisions regarding materials, structural design, and user-friendly features. Conjunctively, you may look to the consumers too. By analyzing consumer behavior, conducting surveys, and studying market trends, brands can gain insights into consumer preferences which helps packaging designers make informed decisions regarding the visual aesthetics, functionality, and features of the packaging.
Successful packaging design is a collaborative effort to balance aesthetics, functionality, and sustainability to create a memorable, impactful solution. And with flexible packaging, finding this balance has never been easier.
Flexible packaging is adaptable and practical, enabling an enhanced user experience and adding value to your product through easy reusability, convenience and sustainability. It even allows creative design elements that captivate potential buyers with its pliable nature allowing for imaginative, innovative shapes, colors, and textures that make products stand out on the shelves.
Even for branding, which is crucial in differentiating products in a competitive market, flexible packaging provides ample space to effectively use creative graphics, logos, and brand messages, ensuring that the packaging design aligns with your brand’s identity and establishes a strong visual connection with consumers.
But even when all of these creative branding and customization options are available for your experimentation, it is essential to remember that structure, protection, and functionality are equally, if not more, important considerations.
Source: PakFactory
The package should prioritize the protection of the product but maintain convenience, ensuring its freshness and integrity while catering to a user-friendly experience that all consumers want. You can do this by carefully selecting suitable materials and considering factors like barrier properties, puncture resistance, and shelf life. Striking the right balance between convenience and protection in your package’s design is critical to meeting consumer expectations and differentiating yourself from the competition.
So what materials should you use to find the balance? Professional packaging designers and manufacturers will help you find the best material for your product, but let’s look into some of the popular materials used in flexible packaging to better understand what’s available.
The choice of materials significantly impacts the overall performance and suitability of any packaging solution, especially for flexible packages. Factors such as product compatibility, barrier properties, and sustainability considerations are pivotal in selecting the appropriate materials that complement and enhance your product.
Regarding flexible packaging materials, several options have gained popularity due to their performance and suitability for different industries:
And though the above materials are all popular and excellent choices for flexible packaging, in a bid for increased sustainability, let’s also look at a few alternate material choices that align with eco-conscious goals.
Using fewer materials or incorporating Post-consumer recycled (PCR) materials is possible for brands looking for an eco-friendly initiative. Another avenue to consider is renewable resources, such as plant-based resins and paper, offering a greener alternative to plastic. Polylactic acid (PLA) film can also be incorporated, providing an industrially compostable option.
Sustainable material options are crucial in reducing the environmental impact, so take note of these options! As more consumers demand eco-friendly initiatives from companies, you will only be limiting yourself if you do not carefully consider all avenues of possible materials in your packaging, including sustainable alternatives.
A circular, sustainable economy is crucial for eco-conscious practices as it minimizes waste and maximizes resource efficiency throughout the product lifecycle. Unlike the traditional linear economic system, a circular economy focuses on reducing waste and pollution, utilizing renewable energy and resources, promoting material circulation and recycling, and aligning supply chains with nature-centric principles.
For flexible packaging, in particular, these practices ensure that it has a minimal environmental impact. Flexible packaging plays a crucial role in the circular economy by using fewer raw materials, facilitating easy recycling and reuse, and enabling composting for biodegradable packaging. By embracing the circular economy, businesses can significantly reduce the carbon footprint of packaging and contribute to a more sustainable future.
But now that you’ve got a better understanding of the plethora of available materials at your disposal, both popular and sustainable, it’s time to dive into the possible printing techniques and graphic designs you can apply to them.
With the many different materials available and various forms of flexible packaging like stand-up pouches, you’ll be pleased to know that you have as many printing options too! You can choose from multiple printing and curing technologies to add colors, text, and graphics to your packaging design, like:
By utilizing these advanced printing techniques and incorporating high-quality images, fonts, and colors that align with your product and brand identity, you can create visually appealing and impactful designs that effectively convey your brand’s message and resonate with your target audience.
So now that you’ve planned the packaging design, have chosen the materials and looked at the printing methods, what’s next? The next step is to meet the industry standards and regulations for this type of packaging. Quality control for flexible packaging involves various tests and measures to ensure its integrity and performance. These tests include:
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These quality control processes are necessary to provide manufacturers with valuable insights into the quality and performance of the flexible package. By conducting these tests, manufacturers can identify any weaknesses or deficiencies in the design or materials, allowing them to make necessary adjustments and improvements. Moreover, adhering to recognized industry standards ensures the package meets the required specifications and consistently delivers reliable performance and compliance.
But quality control is for more than just controlled environments. The global supply chain faces increasing challenges in ensuring product safety. Food recalls have increased, with microbial contamination and unsanitary handling significant contributors. Rigorous testing is necessary throughout the entire supply chain to protect consumers and minimize health risks.
Compliance with regulations and certifications across the board is crucial to ensure the health and safety of consumers by meeting stringent standards for material safety, hygiene, and product quality. Certifications such as FDA, CFIA, and EU compliance demonstrate adherence to specific regulatory frameworks and allow brands to provide assurance to consumers, build trust, and contribute to responsible and ethical packaging.
If you are still unsure whether to use flexible packaging for a safer convenient, and more sustainable alternative to traditional packaging, let’s look at a quick example of a big company, Nestle, and how they actively incorporate this type of packaging.
Source: Unsplash
Nestle has implemented a comprehensive sustainability initiative that embraces flexible packaging as a key product element. This initiative revolves around the three core principles of better packaging, less packaging, and better systems.
In pursuing better packaging, Nestle aims to reduce its reliance on virgin plastic by actively seeking alternatives and exploring innovative solutions. This includes piloting reuse and refill systems, increasing the utilization of paper and flexible packaging, and supporting the development of efficient collection, sorting, and recycling systems in the countries where the company operates.
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To create a better system for packaging waste management, Nestle collaborates with partners globally to address the infrastructure challenges associated with collection, sorting, and recycling. Through joint projects and activities, Nestle seeks to model successful collection schemes and promote establishing well-functioning systems.
Through its dedication to sustainable packaging practices, Nestle actively contributes to the transition towards a circular economy, where resources are managed efficiently, waste is minimized, and environmental sustainability is prioritized.
Flexible Packaging is relatively new. With this being said, innovation and evolution are constantly occurring, and this alternative solution to traditional packaging is only getting better and more advanced with time.
Innovations in smart packaging are beginning to coalesce and merge with flexible packaging. Advanced sensors and indicators can now monitor product condition, ensuring freshness and safety throughout the supply chain by detecting spoilage and filtering out harmful agents that might invade the package. And with the recent introduction of QR codes, RFID tags, and NFC, vital information is now provided to consumers, which helps prevent theft and counterfeits. Smart packaging solutions specifically designed for flexible packaging only improve product quality further, empower consumers with information, enhance brand relevance and ensure food safety.
Source: Unsplash
Flexible packaging is rapidly gaining popularity due to its convenience, lightweight nature and positive environmental impact. This is only further enhanced when combined with smart packaging and its advanced innovative technologies. Soon, this type of packaging will no longer be the alternative. It will become the standard across many industries with its versatility and ability to adapt to consumer preferences for sustainability and user-friendliness.
Flexible pouch packaging has revolutionized the packaging industry with its versatility, sustainability, and application across a wide variety of industries. In this article, we will cover what flexible pouch packaging is, the benefits of using it, different types of flexible pouch packaging, when to use it, and examples of some leading pouch suppliers on Impacked.
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Flexible pouch packaging is packaging made from flexible materials that can be easily shaped and customized to accommodate various products. Flexible pouches adapt their shape to the contents they hold offering unique advantages in storage, transport, and presentation. Available in a wide range of materials including eco-friendly solutions, pouch packaging is commonly used in industries ranging from food and beverages to personal care and pharmaceuticals. Flexible pouches provide a practical and efficient solution for both brands and consumers.
Flexible pouches use less material than traditional rigid packaging, which can result in a net material reduction when switching a product from rigid packaging to flexible packaging. Through using less material, pouches can also take up less space compared to rigid containers, both on store shelves and during transportation.
Flexible pouches can be easily customized in size, shape, material, and dispensing method, making them suitable for a wide range of products. This versatility allows businesses to design stand out primary packaging across a wide variety of industries. Additionally, high-quality printing techniques can be used to display vibrant graphics and essential product information.
Flexible pouches offer excellent barriers against moisture, oxygen, light, and contaminants, ensuring that the contents remain fresh and safe for extended periods. This can provide a potential benefit in extending the shelf life of your product.
Pouches are lightweight, sometimes portable, and easy to use. Features such as resealable zippers, spouts, and tear notches enhance user experience, making it easier for consumers to open, close, and dispense the contents.
Flexible pouches are ideal for e-commerce due to their lightweight nature and durability. They reduce shipping costs due to improved value density and can withstand the rigors of transit, helping reduce chargebacks, returns, and negative reviews from damaged products.
While applicable across a wide variety of industries, there is not one size fits all approach to flexible pouch packaging. Understanding the best type of flexible packaging for your innovation is important, here are the five most common types of flexible packaging:
As the name would suggest, stand-up pouches are designed to stand upright on their own, providing a shelf presence that is usually achieved with rigid packaging. They are often used for snacks, pet food, and beauty & personal care refill products. These pouches are often used with resealable zippers or valve fittings.
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Gusset pouches have expandable sides or bottoms that provide additional space and stability. The most common application for gusset pouches is coffee packaging, but they are generally a good choice for bulkier items.
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Flat bottom pouches combine the benefits of gusset and stand-up pouches, offering maximum storage capacity and a stable base. This type of pouch is suitable for a variety of products and often comes with a “window” so people can see the contents of the product.
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Sachets are small, single-use pouches commonly used for beauty and personal care samples or individual servings of products like condiments, powders, and supplements. Sachets come in a variety of styles and shapes including tandem sachets (a strip of sachets) or custom shapes, known as die cut sachets.
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Stick packs are narrow, tube-like pouches used for single servings of powders or liquids. They offer convenience and precise portion control, making them popular for drink mixes, nutritional supplements, and pharmaceuticals.
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Flexible packaging pouches can be further customized by their dispenser. Dispensing type will matter depending on the product being packaged. Considerations when picking your dispenser type should include if the pouch is single use or resealable, contains solids or liquids, and if the consumer will need to move the product around regularly.
Zipper pouches offer a resealable option that maintains product freshness and enhances multiple use convenience. These pouches are commonly used for food products, pet food, and household items, providing easy access and closure.
Valve pouches are essential for products that release gasses, such as coffee. The valve allows the gas to escape without compromising the pouch's integrity, maintaining product freshness and quality.
Spout pouches are often used for liquid products, providing a convenient way to pour and reseal the pouch. They enhance user convenience and reduce spillage, making them ideal for non-solid formulas like beauty product refills, beverages, sauces, and liquid detergents. Spout dispenser can be used across a wide variety of pouches including smaller sized sachets for samples.
Handle tear pouches are one of the most common dispensing methods for pouches as they are often the most cost effective dispensing type. This type of dispenser makes the pouch easy to open and can be used across a wide variety of flexible packaging including sachets and stick packs. Handle tear dispensers are used in the market extensively in categories ranging from snacks to personal care items.
Polyethylene is widely used in flexible packaging due to its durability, flexibility, and excellent moisture barrier properties.
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Polypropylene offers high clarity and good barrier properties. PP pouches are often used for snack food packaging, as well as for products that require a high level of transparency.
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Aluminum foil is used in flexible packaging for its superior barrier properties against light, oxygen, and moisture. It is commonly used in packaging for perishable goods and products that require extended shelf life. Often times, aluminum foil is used a one of many layers in flexible pouch packaging.
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Paper-based flexible packaging is an eco-friendly option that has gained popularity over the last few years. Paper based flexible packaging is often either biodegradable or recyclable and can be a great way at bringing a sustainable proposition to life.
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Flexible pouches are ideal for sample and trial sizes, allowing consumers to try products without committing to full-size purchases. This is particularly useful for cosmetics and personal care and tends to be a sachet styled pouch. Impacked has a dedicated sample and trial size catalog of components.
Pouches are perfect for sports drinks, protein powders, and supplement mix-ins. In particular, zipper and tear pouches fit these categories well depending on if the product is single or repetitive use.
Laundry detergent pouches are convenient, easy to store, and reduce plastic waste compared to traditional bottles. Two common applications in the laundry space are pouches for laundry pods and pouch refills for liquid detergent.
Flexible pouches preserve the freshness of coffee, with options like resealable zippers and valves for optimal storage. We see many materials used for coffee packaging including kraft paper, polypropylene, and aluminum foil.
Pouches are a great option for pet food packaging. The lightweight, easy to handle design of pouches helps consumers store and dispense pet food easily. They offer convenience with resealable options and are popular among pet owners.
With an idea of what type of flexible packaging is right for your next product, lets try and find you a supplier that can bring your next project to life. Here are some of the top flexible pouch packaging suppliers listed on the Impacked:
Identipak specializes in high-quality sachets and stick packs which can be used across a wide array of industries. Perfect for sample packaging, Indentipak has robust custom packaging capabilities if you’re interested in die cut patterns.
Specialities: Sachet Packaging, Stick Packs, Custom Designs
Source Identipak Components
Elk Packaging is well known for their sustainable and environmentally-friendly stand up pouch and sachet solutions. Elk Packaging products compostable pouches in addition to pouches which can be recyclable or made from recycled materials.
Specialities: Compostable Pouches, PCR Pouches, Recyclable Pouch Packaging
Source Elk Packaging Components
Based in New Jersey, eXpack offers a wide range of flexible packaging solutions included spouted pouches and sachets, handle tear pouches, stick packs, and their own custom flexible packaging called the Unisolve. eXpack works extensively with beauty brands but also has FDA and OTC quality certifications.
Specialities: Beauty Products; sachets, sticks, and spouted pouches
Source eXpack Packaging Components
Xela Pack is known for its environmentally conscious packaging options, prioritizing sustainability without compromising on quality and functionality. Xela Pack small sized stand up pouches ideal for liquids, powders, and tablets in the food, natural health, cosmetics, and pharmaceuticals space. Xela Pack has designed their own custom pack, the Xela Pack, which is designed to minimize product waste
Specialities: Small Sized Packs, Pill & Powder Packs, Eco-Friendly Solutions
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