When to Use custom pouch manufacturer？

In today's competitive market, packaging plays a crucial role in catching the eye of potential customers and boosting sales. When it comes to pouch packaging, businesses have two main options custom printed pouches and stock pouches. But which one is the best fit for your brand? 

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Key Takeaways

Custom Printed Pouches

Stock Pouches

Tailored to your brand

Ready to use

Higher upfront costs

Lower initial investment

Longer lead times

Quick turnaround

Minimum order quantities

Flexible order sizes

Enhanced brand visibility

Limited branding options

Customisable features

Standard features

What Are Custom Printed Pouches?

Custom printed pouches are packaging solutions designed specifically for your brand. They allow you to create unique packaging that stands out on the shelf and reflects your company's identity. With custom pouches, you have control over the design, colours, logos, and even a range of finishing extras taht can be added. This level of customisation ensures that your packaging aligns perfectly with your brand image and product requirements.

Customisation Options

When opting for custom printed pouches, you have a wide range of options to choose from:

1. Materials:
• Plastic films
• Foil laminates
• Paper-based options
2. Pouch Types:
• Stand up pouches
• Flat bottom bags
• Spout pouches
• And many more, all of the pouches on the Polypouch website can be customised
3. Printing techniques:
• Digital printing for short runs and intricate designs
• Flexographic printing for large volumes and consistent results
• Kraft overprinting for short runs onkraft pouches

These options allow you to create packaging that not only looks great but also functions perfectly for your specific product.

The Custom Pouch Production Process

Creating custom printed pouches involves several steps, ensuring that the final product meets your exact specifications. The process typically begins with a design consultation, where you'll work with packaging experts to determine the best options for your brand. This is followed by artwork preparation and proof approval, ensuring that the design looks exactly as you envision it.

If flexographic printing is used, the next step is plate making. Then comes the actual printing process, followed by laminating if required. The pouches are then cut and shaped to the specified dimensions. Before being packed and shipped, each batch undergoes rigorous quality control to ensure that every pouch meets the high standards you and your customers expect.

Another option includes one of many online packaging design tools that now exist such as the Polypouch Pouch Creator. These tools are essentially a print on demand service allowing you to either upload professionally designed artwork or design your pouch packaging on the go within the tool. These tools are able to offer much lower MOQ print runs. See the overview blog post about the Polypouch tool to gain a better understanding of how this tool works.

What Are Stock Pouches?

Stock pouches are pre-made packaging options that are readily available for purchase. They come in standard sizes, shapes, and materials, making them a quick and easy solution for many businesses. While they don't offer the same level of customisation as custom printed pouches, they do have several advantages that make them attractive for certain situations.

Stock pouches are available in various types to suit different needs:

1. Resealable zipper pouches
2. Spout pouches for liquids
3. Flat bottom bags for stability
4. Three-side seal pouches
5. Stand up pouches

They typically come in standard sizes, such as 100g, 250g, 500g, and 1 kg etc, with materials includingclear plastic, metallic films, and kraft paper blends.

One of the main benefits of stock pouches is their immediate availability. When you need packaging quickly, stock pouches can be an excellent solution. They're also more cost-effective for small orders, as there are no setup fees or minimum order quantities to worry about.

Custom Printed Pouches vs Stock Pouches How Do They Compare?

Now that we've covered the basics of both custom printed pouches and stock pouches, let's look at how they compare in key areas that might influence your decision.

Brand Identity and Marketing

Custom pouches give your brand a unique voice on the shelf. With full control over colours, logos, and designs, you can create packaging that truly represents your company's identity. For example, a gourmet coffee or tea brand might use custom pouches with rich colours and gold foil accents to convey a premium image. This level of customisation can significantly enhance brand recognition and appeal to your target market.

Stock pouches, while functional, offer limited branding opportunities. You might be able to add a label or sticker which will take time to apply and not all pouches will be exactly the same, but the overall look will be more generic. This could work for some brands, like a small local farm selling produce at a farmers' market, where simplicity is part of the appeal. However, for brands looking to stand out in a crowded market, the limitations of stock pouches might be a significant drawback.

Cost Considerations

When it comes to costs, there are several factors to consider:

• Initial investment: Custom printed pouches often have higher upfront costs due to design fees and setup charges. Stock pouches have lower initial costs, making them attractive for businesses with tight budgets or those just starting out.
• Per-unit costs: For high-volume orders, custom pouches can become more cost-effective over time. As order quantities increase, the per-unit cost typically decreases. Stock pouches maintain a steady price point, which can be higher per unit for large orders compared to custom options.
• Minimum order quantities: Custom pouches often have higher minimum order quantities (MOQs) due to the setup involved in the printing process (with the exception of kraft overprint). Stock pouches offer more flexibility, allowing you to purchase smaller quantities as needed.

Lead Times and Flexibility

The production of custom pouches takes time. From design approval to manufacturing and shipping, you might be looking at a lead time of 4-6 weeks or more. This longer lead time needs to be factored into your planning and inventory management.

Stock pouches, on the other hand, offer quick turnaround times. In many cases, you can receive your order within a few days. This makes stock pouches an excellent option for businesses that need packaging quickly or those with fluctuating demand.

Product Protection and Functionality

With custom pouches, you can tailor the packaging to your product's specific needs. This might include:

1. Extra barrier layers for sensitive products
2. Custom shapes for unique items
3. Special closures for user convenience
4. Dispensing features for liquids or powders
5. Window panels for product visibility

This level of customisation ensures that your packaging not only looks great but also provides the best possible protection and functionality for your product.

Stock pouches offer basic protection and functionality. While they may be suitable for many products, they might not meet specific requirements for items that need special care. If your product has unique needs in terms of preservation, dispensing, or storage, custom pouches might be the better option.

Environmental Impact

Sustainability is an increasingly important consideration in packaging decisions. When designing custom pouches, you have the opportunity to choose eco-friendly materials and printing processes. This might include options like recyclable mono-material films, compostable materials, or water-based inks.

Many suppliers now offer stock pouches made from sustainable materials as well, though your options may be more limited compared to custom solutions. When considering the environmental impact, it's important to look at the entire lifecycle of the packaging, from production to disposal or recycling.

When to Choose Custom or Stock Pouches

The choice between custom printed pouches and stock pouches ultimately depends on your specific business needs and circumstances. Here are some scenarios where each option might be the better choice:

Custom printed pouches are ideal for:

• Brand launches or rebrands
• Products in highly competitive markets
• Premium or luxury items
• Products with unique shapes or sizes
• Businesses looking to enhance brand recognition

Stock pouches can be the right option when:

• You're working with a tight budget
• You need packaging quickly
• You're testing a new product
• Your order volumes are low or inconsistent

The Future of Pouch Packaging

As technology advances, we're seeing exciting developments in both custom and stock pouch options. New printing techniques are making it easier and more affordable to create eye-catching custom pouches. Digital printing, in particular, is opening up possibilities for short-run custom orders, variable data printing for personalised packaging, and photorealistic imagery on pouches.

Both custom and stock pouch manufacturers are focusing on sustainability, developing new materials and designs that reduce environmental impact. Some key trends include:

1. Mono-material pouches for easier recycling
2. Bio-based films from renewable resources
3. Reusable pouch designs
4. Compostable materials for eco-friendly disposal
5. Smart packaging with QR codes or NFC technology

Making the Right Choice for Your Brand

Choosing between custom printed pouches and stock pouches comes down to carefully considering your specific needs. Think about your brand identity and marketing goals, budget constraints, time frame, order volumes, and product requirements. By weighing these factors, you can select the pouch packaging solution that best fits your business and helps your products shine on the shelf.

Remember, your packaging is often the first thing a customer sees. Whether you choose custom or stock pouches, make sure your selection aligns with your brand values and meets your customers' expectations. The right packaging choice can significantly impact your product's success in the market.

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!

1. Why Flexible Pouches? Understanding Their Benefits

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:

• Reduced Costs – Less material is used than traditional packaging, making pouch production more cost-effective.
• Enhanced Visibility and Aesthetic Appeal – A pouch’s ability to stand upright and its unique appearance give it a strong shelf presence.
• Convenience and Portability – Its lightweight and slim profile that takes up significantly less space when filled or unfilled helps reduce shipping costs and allows efficient storage and distribution. The Flexible Packaging Association equates one truckload of empty flexible pouches to 26 truckloads of empty glass jars.
• Extended Shelf Life for Your Products – Pouches come with barriers and special films that prevent external factors such as odours, oxygen, light, and bacteria from contaminating a product while keeping refrigerated items fresh for extended periods.
• Environmental Benefits – The Flexible Packaging Association revealed in a publication that flexible pouches use 75% less energy and generate a tenth of CO2 emissions during production than metal containers of equivalent products.

2. Premade vs. Custom Pouches – Which One is Right for You?

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.

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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!

3. The Types of Pouches You Can Have

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.

3.1 Stand-Up 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.

Block Bottom (Flat Bottom) Style

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 Style

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.

The three main types of bottom gusset pouches available to you include;

• Plow-Bottom Pouch
• Doyen-Style Pouch
• K-Seal Stand Up Pouch (K-Style) with Skirt Seal

Side Gusset Style

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.

3.2 Flat Pouches

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;

Pillow Pouch Style

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-Side Sealed Style

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.

Four-Side Sealed Style

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.

3.3 Roll Stock

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.

3.4 Custom Shaped Pouch

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.

4. Choosing the Right Materials for Your Pouch

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 for Durability and Versatility

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;

• Polyethylene (PE)
• Nylon
• Polyethylene terephthalate (PET)
• High-density polyethylene (HDPE)
• Low-density polyethylene (LDPE)
• Cast polypropylene (OPP/CPP)

Metal Foil for Superior Barrier Protection

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 for a Natural Look and Sustainability

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 for Reduced Environmental Impact

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.

5. Customization Options for Your Pouches

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.

Fitments and Closures

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;

• Easy dispensing pouches with a tear notch are ideal for liquid, gel or lotion samples.
• A Tear Notch or slit is a perforated top that allows for an easy opening process. You can also feature tear notches with other options like zippers for resealability.
• Press-to-close zippers are an excellent and cost-effective option that allows your pouch to be conveniently closed and reopened.
• Sliders are easy and fast to open and reclose. They offer your consumers the convenience and assurance that the pouch is closed correctly.
• A Spout Pouch features a re-closable nozzle for easy access to liquid products.
• Resealable films allow consumers to open and reseal a pouch using tamper-evident methods for safety and convenience.
• A degassing valve is excellent for products like coffee that use stand-up pouches. The one-way valve vents CO2, allowing products to stay fresh for longer.
• Tin ties add a quick way for consumers to close a pouch and are popular for baked goods.

Merchandising Features

These customization options help display your pouch on store shelves and attract potential customers with convenient additions to your packaging. Options include;

• Hang/Peg holes that enable a pouch to be placed on hangars or hooks.
• Display Windows on a stand-up pouch lets consumers see the product inside the package.
• Carry-hole handles provide an accessible and comfortable place for customers to carry a pouch bag without worrying about dropping it.

Barriers and Coatings

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;

• Moisture Protection prevents food from losing moisture or protects against moisture for dry foods.
• Grease Resistance/Grease-Proofing protects the package and maintains hygiene by resisting grease transfer from product to package.
• Gas and Aroma Barriers prevent contaminants such as oxygen from entering a package and causing spoilage or prevent gasses from escaping.
• Additional Heat Resistance gives a pouch extra resistance against hotter temperatures.

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.

Material Structures and Layers

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;

• The print/ink and coating layer is the outermost layer used for branding and design. It affects a package’s overall look and feel while providing product information to consumers.
• Structural layers give a pouch its strength, durability and puncture resistance.
• Barrier layers protect a product from odor, oxygen, light, and bacteria.
• Sealant layers protect from leaks and provide functionality for other customizations like closures, fitments and resealability.
• Tie layers are what bond structural and barrier layers together.

6. Pouch Treatment and Filling Methods

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;

Manual Filling

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

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.

Retort Packaging

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.

Hot-Filled

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.

7. Printing Techniques for Your Custom Pouch

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 Printing

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.

Rotogravure Printing

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.

Digital Printing

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.

8. Looking for a Custom Pouch Packaging Partner?

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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