Custom flexible packaging — 500-unit minimum.

Flexible packaging is any package that holds its shape only when filled — pouches, sachets, rollstock and bags made from film rather than board. It is the lightest way to pack most products: a stand-up pouch uses a fraction of the material and shelf space of a rigid box, and it ships flat before it is filled.

It does most of the same jobs as a box — protection, shelf presence, branding — with less material and lower freight. The trade-off is that film is less protective against crushing, so it suits products that do not need structural support. It is the usual choice for food and beverage, supplements and beauty; where a product needs structure, a rigid box is the alternative.

Most flexible packaging falls into a handful of formats. The right one depends on how the product is filled, how it is stored, and how it is opened.

• Stand-up pouches — the workhorse. A gusseted base lets the pouch stand on a shelf; used for coffee, snacks, powders and liquids.
• Flat and three-side-seal pouches — the simplest form, sealed on three edges. Good for single servings and sample packs.
• Zipper and resealable pouches — for anything used over time. A press-to-close or slider zipper keeps the product fresh between uses.
• Spouted pouches — a fitment for liquids and gels, so the pouch can be poured or squeezed.
• Rollstock and film — unprinted or printed film supplied on the roll, for packers running their own form-fill-seal lines.
• Vacuum and high-barrier bags — for meat, cheese and anything that needs the air out or a specific shelf life.

Film is chosen for what it has to keep out. A single layer is enough for dry goods; anything with oils, moisture or a shelf-life requirement needs a laminate — usually a printed outer layer bonded to a barrier layer and a sealant inside.

• PET / PE — the standard printed pouch. Good print surface, decent moisture barrier.
• PET / foil / PE — adds a foil layer for a strong light and oxygen barrier; used for coffee, snacks and supplements.
• Kraft paper laminates — a paper outer for a natural look, with a film or foil layer inside doing the actual work.
• Recyclable mono-material films — a single polymer so the pouch can enter a recycling stream, at some cost to barrier performance.

Printing is usually flexographic for film, with digital available for short runs. Finishes are matte, gloss or soft-touch, and the seal can be a zipper, a spout, a tear notch or a hang hole.