Adhesive Lamination In flexible packaging, we use "laminating" to create barrier films by bonding multiple layers with adhesive. We apply adhesive to the less absorbent substrate to ensure a durable bond. This process creates packaging that protects products from outside elements and extends their shelf life. AI (Aluminum/Foil) Packaging materials need a superhero, and that's […]
In flexible packaging, we use "laminating" to create barrier films by bonding multiple layers with adhesive. We apply adhesive to the less absorbent substrate to ensure a durable bond. This process creates packaging that protects products from outside elements and extends their shelf life.
Packaging materials need a superhero, and that's where aluminum/foil comes in! We laminate these thin sheets of metal to the inside of your packaging to provide unbeatable protection against oxygen, aroma, and water vapor. Think of it as a fortress wall that shields your precious goods from any nasty external elements that will spoil quality or freshness. With aluminum or foil in place, you can rest easy knowing that your products are protected and ready to go the distance.
These specially designed materials form a protective layer against water, oils, and gasses that can spoil your products or leave them looking and tasting less than stellar. By keeping these pesky invaders out, barrier materials help your products stay fresher, longer. Plus, with their superpowers, they help ensure your products are as effective as possible, so you can feel confident that your customers are getting the very best.
These special plastic films have been engineered to create a tough shield against all kinds of external threats, from water to gasses to oils. These films include types like Polyester (PET), Polypropylene (BOPP, CPP), Polyethylene (LLDPE), Nylon, and metalized films with a thin layer of aluminum for enhanced barrier properties. With these powerful tools at your disposal, your products can conquer anything the outside world throws their way!
Impermeability is a material's superpower to block the passage of gasses, liquids, and other substances. This means that the material provides a powerful shield that protects against all kinds of unwanted intruders, keeping your products at its peak freshness and quality, safe and sound.
Biaxially-oriented plastic film is a true hero of the packaging world! It's made by stretching the film in both primary directions, both in-line and perpendicular, which gives it unbeatable mechanical properties like superior tear strength and incredible uniformity. With biaxially oriented film on your side, your packaging is guaranteed to stay strong and stand up to even the toughest challenges.
Biaxially oriented polypropylene (BOPP) is film stretched in both directions, ensuring that it has unbeatable properties like excellent moisture resistance, crystal-clear optical clarity, and incredible tensile strength. No wonder BOPP is so widely used—it's a packaging powerhouse that guarantees your products are always well protected.
Refers to eco-friendly materials that can be decomposed by bacteria and other living organisms, reducing their impact on the environment. Biodegradable materials are an essential component of sustainable packaging and are becoming increasingly popular in the packaging industry.
A.K.A. “bubble extrusion,” blown film is a tried-and-true method for producing all kinds of plastic films. Molten plastic resins are extruded through a tube to create a thin bubble, which is then expertly guided through rollers and cooled with surrounding air. This process enables us to create films with a wide range of properties, like unbeatable flexibility, crystal-clear transparency, and incredible strength. With bubble extrusion, the possibilities are endless!
Glossy cast Polypropylene boasts unbeatable heat resistance and heat sealable properties, making it the perfect choice for retort packaging. In fact, it's commonly used as the main heat seal layer for this type of packaging.
With this technique, molten plastic resins are expertly squeezed out through chilled rollers, locking their configuration and properties in place. The result? High-quality films with great consistency and performance.
Keeping little ones safe is a top priority for any responsible manufacturer. That's why child-resistant packaging closures are such an important tool in the fight against accidental ingestions. These innovative plastic zipper closures are designed to reduce the risk of children opening a package and coming into contact with potentially harmful or hazardous products. With child-resistant packaging closures, you can rest easy knowing that you're doing everything in your power to protect your customers' little ones from harm.
Coextrusion is an innovative film manufacturing process that allows for the extrusion of multiple layers of film at the same time. By combining different materials, coextrusion creates a single film with unique properties that can't be achieved with individual components alone. The resulting laminate is seamless, with a wide range of benefits such as enhanced barrier properties and improved strength.
Cold sealing is a pressure-activated sealing process that allows for a strong and reliable seal without the need for heat. It uses a specially formulated adhesive coating on the sealing layers that can seal the package without causing any damage or melting to the product inside. Cold sealing is a great solution for products that require careful handling, such as pharmaceuticals, chocolates, or other heat-sensitive items.
Compostable products break down into non-toxic components with the help of heat, water, oxygen, and microorganisms, returning valuable nutrients to the soil. Not all biodegradable materials are compostable, but compostable materials are always biodegradable. They're a great choice for eco-friendly packaging solutions that prioritize sustainability and reduce environmental impact.
The process of blending two or more resins or additives to create a material with unique and specific properties is known as compounding.
A company that "converts" raw materials into finished products, such as flexible packaging or labels.
Copolymer resin are plastics that are created by putting together small building blocks called monomers. These monomers join together in a process called polymerization, resulting in a type of plastic that is clear, tough, and flexible.
By subjecting a plastic film to a high-frequency electrical discharge, the corona treatment increases the film's surface energy, resulting in improved adhesion of inks, coatings, and laminates. This process helps ensure that printed or coated surfaces don't peel off or lose their quality during use, making it an essential step in the production of high-quality flexible packaging.
A die-cut pouch is a type of flexible packaging that is custom-made to fit the specific product being packaged. It is created by using a cutting die, which is a tool used to cut and shape materials, to cut out the desired shape of the pouch from a roll of material. Die-cut pouches can be made in a variety of shapes and sizes, and can have features such as zippers, tear notches, and hang holes added to them during the manufacturing process.
The Doyen seal is the ultimate classic in stand-up bags! It is one of three types of stand up pouches, along with K-seal and plow bottom pouches. This popular design features a rounded oval bottom with welded corners for extra support, making it a breeze to stand upright on store shelves. The sealing area carries the weight of its contents, so it's perfect for lighter items (up to one pound). No matter what your needs are, you can find the perfect size to fit your product. Keep in mind, the standard size is usually a bit on the smaller side, but hey, good things come in small packages!
Extrusion Lamination is a process of bonding two layers of material without using an adhesive bonding agent. It involves extruding a layer of molten plastic, usually a "tie layer" of polyethylene, to bond the two layers together. This method is not as commonly used in the food and beverage industry, but it offers excellent barrier properties.
EVOH (Ethylene Vinyl Alcohol) is a special type of plastic that is really good at keeping oxygen out. However, it's not very good at keeping water vapor from passing through. To solve this, we often sandwich EVOH between two other layers of plastic to keep its oxygen-blocking properties while still allowing for a barrier against moisture.
The flat bottom pouch is a flexible packaging pouch that provides structural support and balance by including side gussets, much like the quad seal pouch. As opposed to the fold-over bottom style of the quad seal pouch, the flat bottom pouch has a bottom that flares out and lays flat (resembling a box). This is a popular choice for packaging coffee beans and other products.
The flat pouch offers a simple and compact packaging solution. Also referred to as a 3-side-seal pouch, the 3-side seal pouch is an affordable packaging option that doesn't feature any gussets. We use less film to produce these pouches, making them a cost-effective solution. We typically use flat pouches for single-serve items or products that aren't easily damaged by bending, such as beef jerky and specific candy products.
Flexographic printing is an age-old technique that has been around since the late 1800s, and it still holds its own in the printing industry today! It involves using rubber plates with engraved images to transfer ink onto various materials. While it may not produce the same color density as rotogravure, it has come a long way in terms of technological advancements and print quality. So even though rotogravure may be the gold standard for flexible packaging printing, flexographic printing is still a versatile and reliable option.
When you need top-notch barrier protection for your product, aluminum foil is often the go-to choice. This versatile material is added to laminate structures to provide unbeatable protection against moisture, oxygen, and other environmental factors. However, when only slightly better barrier properties are needed, metalized films can be used instead of foil. One key difference is that foil is a separate layer in the laminate, while metalized film is a plastic film that has been coated with a thin layer of aluminum. So whether you need maximum protection or just a little extra, the right choice of barrier material can make all the difference in keeping your product fresh and protected.
Imagine creating a package that is not only visually appealing but also cost-effective and efficient to produce. Enter the form-fill-seal (FFS) process, a streamlined manufacturing method that allows the simultaneous creation, filling, and sealing of a package in one go. By using printed rollstock, FFS creates a variety of packaging products such as pouches, bags, and sachets. From chips to snack packs, the FFS process is widely used in the packaging industry for single-serve items. Not only does it save time and reduce manufacturing costs, but it also delivers high-quality, reliable packaging. With FFS, you can be sure that your products will be shelf-ready in no time.
Gas flush packaging, A.K.A., modified atmosphere packaging, works by replacing the air inside the package with a special gas like nitrogen or carbon dioxide. Not only does it help prolong the shelf life of your products, but it also prevents them from getting stale and losing their flavor due to oxidation.
Gravure printing is a top-notch printing technique that produces stunning and uniform images with incredible color depth and precision. This printing process involves engraving an image onto a cylinder and then transferring ink onto the substrate using a doctor blade. Gravure printing is especially well-suited for printing on flexible packaging films and labels, and it offers unbeatable quality for those who demand nothing but the best.
A gusset is an added material that provides reinforcement at a corner or seam of a flexible pouch. Typically folded inward to create a wider base, gussets are commonly found at the bottom of stand-up pouches. They provide structural support to the pouch, allowing it to maintain its shape and stand upright.
A hang hole is a handy feature that allows you to hang your product packaging via hooks on retail shelving. The round or sombrero hang holes are two of the most popular types that make it easy to display your products in a retail setting. This feature is especially useful for products such as snack foods, pet treats, and health and beauty items that need to be easily accessible and visible to consumers. With a hang hole, your packaging not only stands out on the shelf, but it can also be conveniently stored without taking up too much space.
High-density polyethylene (HDPE) is a popular plastic material that is strong, lightweight, and flexible. Its versatility makes it a popular choice for packaging a wide range of products, including food, cleaning products, and personal care items. HDPE is also easily recyclable, both in rigid and flexible forms, making it a more sustainable packaging option.
A heat-seal coating is a layer of special adhesive resin that we apply to a film. This coating enables the film to bond with another film during the heat-sealing process, creating a strong and durable seal. We commonly use heat-seal coatings in flexible packaging to create a seal between two films or between a film and a rigid substrate. This process is essential in ensuring that the packaging is secure and able to protect the product inside from external factors such as moisture and air.
A heat seal is the product of the heat sealing process, which applies heat and pressure to seal flexible packaging. It involves softening the plastic layers with a low melting point, which initiates the seal, and then cooling the packaging to allow the layers to set.
This is the final seal strength of a heat seal after it has been cooled.
Hot tack strength refers to the strength of a heat seal while it is still hot, before it has been cooled. This property is critical in high-speed packaging applications where there is a risk of the seal opening during the process.
Impulse sealer, also known as a heat sealer, seals packaging materials by applying a controlled amount of heat and pressure. It is a machine that is widely used in the packaging industry to create a secure and consistent seal on a variety of plastic materials, such as bags, pouches, and other packaging types.
With a unique "K" shaped bottom gusset, this style can support products up to 5lbs while still standing up tall on store shelves. It is one of three types of stand up pouches, along with doy seal/doypack and plow bottom pouches. Its angled corner seals provide great strength and stability, preventing breaks and tears that could compromise your product. The K-style bottom gusset is a popular design in stand-up pouches, providing ample space for your product and a professional appearance that will grab consumers' attention.
A laminated film is created by combining two or more barrier films using an adhesive or extrusion process. This creates a strong and durable material that we form into a variety of packaging types, including flexible pouches. The combination of different films in the laminate can provide enhanced properties such as barrier protection, puncture resistance, and heat resistance, making it a popular choice for packaging food, pharmaceuticals, and other sensitive products.
LDPE, or low-density polyethylene, finds wide usage in the packaging industry due to its soft, flexible nature, and low melting point. It is a popular material for packaging a variety of products, such as bread, produce, and frozen foods. One of the most common examples of LDPE packaging is the sandwich bag, which is known for its flexibility and durability.
LLDPE is a copolymer with excellent heat seal properties commonly used as the inner layer of flexible packaging. It is similar to LDPE in terms of flexibility but has a higher tensile strength and better resistance to impact and puncture.
MRFs sort, clean, and separate materials such as plastic, glass, and paper for further processing into new products. They play an important role in recycling flexible packaging materials, which can be challenging to recycle due to their complex, multilayered structures.
A matte finish is a flat, non-shiny look used to play up image texture and is less susceptible to shine and fingerprints. We commonly use this type of finish in packaging for products like cosmetics, personal care items, and food products.
We often use Met BOPP, a BOPP film coated with a thin layer of aluminum, as a packaging solution in the food industry. This type of packaging is ideal for products like snacks, candy, and baked goods, as the metalized layer provides a reliable barrier to moisture, light, and oxygen. By keeping these elements out, products remain fresher for longer periods.
Metalized films are a game-changer in the flexible packaging world. They consist of a plastic film that has been coated with a thin layer of metal, usually aluminum, to boost its barrier properties. These films are a cost-effective and environmentally-friendly alternative to foil in laminates, providing a comparable level of barrier performance. We use metalized film for packaging of various products, such as snacks and confectionery, to prevent moisture, light, and oxygen from compromising product freshness.
A metallic finish is a glossy coating that gives a product a metallic look, often used to enhance colors and deepen saturation in artistic images. This finish can add shine and dimension to packaging designs for various products, from cosmetics to consumer electronics.
MET PET is a variant of PET film that offers improved barrier properties to oxygen and water vapor, making it more suitable for packaging products that require extended shelf life. While it shares the same properties as PET, MET PET has a thin layer of metal, usually aluminum, deposited on its surface, which provides the added barrier protection. This makes it a popular choice for packaging products like coffee, tea, and pet food.
MVTR, or Moisture Vapor Transmission Rate, is a measure of how easily water vapor can pass through a substance over a given period of time. It is an important property to consider in packaging materials as moisture can negatively impact the quality and shelf life of products. A low MVTR indicates that a material has a high resistance to moisture transmission and would be an ideal choice for packaging products that are sensitive to moisture, such as electronics or pharmaceuticals.
OTR stands for Oxygen Transmission Rate, and it is a measure of how much oxygen can pass through a material in a given amount of time. This is an important property to consider in packaging, as it can affect the freshness and shelf life of certain products, particularly those that are sensitive to oxygen. The lower the OTR of a packaging material, the better it is at preventing oxygen from permeating through and affecting the product inside. Therefore, OTR is often used as a quality control measure for packaging materials and is tested using specialized equipment.
PE, or polyethylene, is a versatile and environmentally-friendly type of plastic. Manufacturers produce PE by polymerizing ethylene gas, which creates long chains of polymer molecules. These chains give PE its high tensile strength and flexibility, making it ideal for use in a wide range of applications. Additionally, PE is resistant to moisture and chemicals, making it a popular choice for packaging products such as food, beverages, and personal care items. Its environmental benefits include being recyclable and lightweight, which reduces transportation emissions.
PET, or polyethylene terephthalate, is a strong, lightweight, and temperature-resistant plastic material. Manufacturers produce PET by polymerizing ethylene glycol and terephthalic acid. We commonly use PET in commercial packaging, including bottles, jars, and trays, due to its excellent barrier properties against moisture and gasses. PET combined with other materials develops improved barrier performance and heat sealability. Additionally, PET is recyclable and can be melted and reprocessed into new products, reducing waste and promoting sustainability.
The plow bottom pouch is a standout option among the three types of stand-up pouches (the others being doy seal/doypack and K-seal pouches), perfect for heavier products weighing over 5lbs. Unlike the other designs, the plow bottom pouch does not have a seal at the bottom, instead, the sides of the pouch extend all the way to the bottom, allowing the product to sit flush. This feature not only offers excellent stability but also creates a larger surface area for your product to rest on. The plow bottom pouch is a versatile and reliable option for packaging products that require maximum support and protection.
PMS, A.K.A. Pantone Matching System, is a versatile color system that has become an industry standard for color matching in printing. This system allows designers and printers to communicate specific colors across different materials and printing methods, ensuring the final product looks exactly as intended. With PMS, you can achieve consistent, accurate, and vibrant colors, making your printed materials stand out. So, whether you're designing a brochure, packaging, or any other printed material, PMS is an essential tool to help you get your desired results.
A polymer is a type of large molecule that is made up of many smaller molecules known as monomers. These monomers are chemically bonded together to form long chains, creating a strong and durable material that we can use for a variety of purposes. Some typical examples include plastics, rubber, and even DNA. Polymers can have different properties depending on the types of monomers used and the way they are bonded together, which makes them versatile materials for many different applications.
PCR stands for Post-Consumer Recycled content, which refers to recovered and recycled materials after consumers have used them. For example, when you throw away a plastic bottle after drinking from it, that bottle can be collected and recycled into a new product, such as a plastic bag. This process helps reduce how much waste eventually ends up in landfills and conserves natural resources, as we can use recycled materials to create new products instead of producing new materials from scratch.
Polypropylene, commonly called PP, is a versatile plastic material businesses use widely in many industries. One of its unique properties is that it has the lowest density among all types of plastics. This means it is incredibly lightweight, making it an ideal material for applications where weight is a concern, such as in the automotive and aerospace industries. In addition, PP is also highly resistant to chemicals, moisture, and impact, making it a popular choice for packaging, food containers, and even medical devices. So, if you're looking for a lightweight and durable plastic material that can withstand harsh conditions, then PP is definitely worth considering!
PTC or P2C is a zipper that puts the power in your customer's hands. Rather than struggling with a difficult-to-open package, PTC allows you to easily open and close your package by simply pulling the brim apart and pushing the ribs together with your fingers. It's a user-friendly design that makes accessing your products a breeze!
PVDC is like a superhero for your packaging! It's a water-based coating that can be applied to plastics like BOPP and PET to make them stronger and shinier. With PVDC, your packaging will be a force to be reckoned with—it'll have improved barrier properties to keep out unwanted moisture and air, plus a glossy finish that will make your product stand out on the shelf. And if scuffing is a concern, don't worry - PVDC will help your packaging stand up to even the toughest handling. So if you want your product to be a real hero on the market, give it the PVDC treatment!
Quality control (QC) is a crucial step in the production process that helps ensure the final product meets the required quality standards. It involves a series of inspections and tests conducted throughout various stages of production to identify any defects or deviations from the expected outcome. The goal is to catch any issues early on to avoid costly mistakes and ensure customer satisfaction. QC is a critical element in delivering a high-quality product and is taken seriously by manufacturers across various industries.
The classic quad seal bag style has been a go-to for packaging for ages, especially for coffee. It is similar to the box bottom bag save for its bottom, which simply tucks in and folds over. The bag is made by sealing the material with side gussets and a folded bottom and top, allowing it to hold 8, 12, or even 16 ounces of product while standing tall on a shelf. The issue is that once the product is removed, the bag's fold-over bottom can lose its stability and cause the bag to tip over.
The Resin Identification Code (RIC), commonly referred to as the recycling symbol, is a number within a triangular symbol that is present on plastic packaging. The symbol serves as a recycling guideline and helps identify the type of plastic material used in the packaging. The RIC is a number from 1 to 7 corresponding to the specific type of plastic, generally found on the bottom of the packaging. This code helps to inform consumers and recycling facilities which types of plastics can be recycled and how they should be processed. Understanding the RIC is essential for ensuring that organizations appropriately sort and recycle plastic packaging, which can help reduce waste and promote sustainability.
We use a slitter machine to convert large master rolls of packaging material into narrower rolls. We then use these narrower rolls to produce various types of flexible packaging, such as pouches, bags, and films. The slitting process involves cutting the master roll into smaller rolls of specific widths, which we can customize based on the specific requirements of the end product. This process is essential for efficient production and helps to reduce waste by allowing all manufacturers to use only the necessary amount of packaging material.
A solvent is a substance capable of dissolving another, such as a liquid that dissolves a solid.
ST PET is a type of film finish that gives packaging a unique, more luxurious texture.
A SKU is a unique code that distinguishes one product from another.
A substrate is any surface on which printing is done.
SUP, or Stand-Up Pouch, is a versatile and innovative packaging design that can advertise your brand on the retail shelf. It's sealed on both sides and bottom gusset, making it durable and resistant to punctures or tears. This pouch can be used for various products, making it an ideal choice for many industries. Choose SUP to make a statement and ensure your product stays fresh and secure.
A tear notch is a small, intentional tear in packaging, allowing for users to easily open the packaging without the need to use any scissors.
VDP is a type of digital printing that allows for unique text and graphics to be printed on each package, making it ideal for product launches, promotions, regional and event marketing. It can also enable brand protection, product authentication, track & trace, and customer loyalty programs.
VOCs are toxic chemicals emitted as gasses from certain solids or liquids, some of which may have short and long-term adverse health effects.
A web is a roll of paper used in web or rotary printing, which is a process where the paper is fed through the press in a continuous roll rather than as individual sheets.
A window is a clever packaging feature that allows you to peek inside and see exactly what's in there. Windows are especially popular in food packaging, so customers can drool over those delicious chocolate chunks or perfectly seasoned chips before they even make the purchase.
Yield is the extent to which film can be stretched without tearing or puncturing. It is an important characteristic for packaging films, as it determines how much the film can be stretched during the manufacturing process.
A zipper that allows you to open and close a packaging bag as many times as you want, keeping the contents fresh and preventing them from spilling out. This feature is not only convenient but also helps reduce waste by extending the shelf life of the product. It's no wonder that zippers are commonly used in food packaging to keep our favorite snacks fresh and delicious!
This versatile packaging style is quick and efficient to fill, and is designed to be sealed on three sides using a specialized machine, leaving the fourth side open for easy filling of your product. Once your product is in place, you can easily seal the fourth side to create a secure and sturdy package that's perfect for a variety of products, from food to beauty items and beyond.
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5 Step Blueprint: How to Design Jerky Packaging Welcome to our full guide on how to design jerky packaging–your definitive resource for crafting custom packaging that not only protects your jerky product but also leaves a lasting impression on customers and drives sales. In this article, we'll dive into actionable insights and provide you with […]
