Filling Process

The first step when considering buying a custom printed pouch (aka mylar bag) is to determine how your product is going to be filled into it. Small businesses, or even larger brands launching new products, typically will do shorter runs and complete the filling process by hand, by putting the product in the pouch and heat sealing it shut with a hand-held or semi-automated machine.

However, fully-automated filling at a co-packer or co-manufacturer can expedite production when hand filling becomes too cumbersome. If you plan on using any kind of automated filling system, it’s important to get feedback on pouch style, material, sizing, or feature placement requirements of the machinery.

Pouch Style

A good next step is to consider what style pouch you want. Pouches intended for lower serving sizes will typically come in a lay-flat configuration and packed into a retail-ready carton.

If the product is bulky, heavy or higher serving count, a standup pouch with an expandable bottom (called a gusset) is a great solution. Standup pouches are beneficial as they allow brand owners to omit the retail shelf carton, because they can stand alone without a secondary support system.

More exotic pouches like box bottom, coffee-style, or shaped pouches are available as well, but come with a higher minimum and extended lead times.

Pouch Materials

Once you have determined a pouch style, the next consideration should be materials. At this point, it’s good to consult with your SunDance packaging specialist to determine the structures that will best suit your product. Some products like solid chocolate have low barrier requirements (or sensitivity to oxygen and moisture), while others, like potato chips, go stale quickly when exposed to open air and humidity of the natural environment.

The material selection process also involves determining the finish of the pouch, and special decoration considerations. We offer gloss, satin matte and soft touch matte options on all of our pouches. You can pair these finishes with special decorations like holographic or glitter effects, or including both gloss and matte finishes on the same pouch.

Pouch Features

SunDance allows you to further customize your standup pouch by offering a unique dual-material format. If you would like to have metallic effects on the front and back of your pouch, but a clear gusset, we can help! This format allows our customers a creative design tool, metalized material for better shelf life, and the capability for consumers to “see before you buy,” to increase confidence in their purchase.

Pouches come with an array of feature options like zippers, tear notches and hang holes. All of our features can be custom selected to fit the specific needs of your lay flat or standup pouch.

Zippers add a resealable element to the pouch, so they are usually found in multi-serving applications. Some markets require a child resistant zipper to keep children from ingesting a product that may harm them or is intended only for medical use. Velcro style (also called hook-and-hook) zippers are becoming increasingly popular for powdered applications like flour and hydration mixes.

Tear notches are a small cut that falls above the zipper that allows the pouch to easily tear open. No scissors needed! A tear notch may be included or omitted based upon your preference.

Hang holes are a great way of adding additional display options at the retail level. Layflat pouches quite often utilize a ¼” circle hang hole, or a sombrero hole, to hang from a pegboard or wall. Including a hang hole is a simple way to ensure easier placement of your product across multiple retail outlets.

Planning Ahead for Multiple SKUs

Another important consideration before buying a pouch is to consider the variety diversification of your product. Are you launching chocolate chip cookies today, but plan to expand into peanut butter and sugar cookies very soon? Our digital printing method allows us to print multiple versions of art at one time, so from an overall buying aspect, it makes more sense to purchase all 3 flavors at once. ie, buying 1,000 chocolate chip today, 1,000 peanut butter next week, and the sugar cookies the week later will be less economical than buying 3,000 pouches today with all 3 flavors. A little planning ahead can save you on overall cost later.

Timelines

Timelines are often a consideration that gets missed until it’s too late. Making a custom printed pouch involves industrial manufacturing equipment that takes time and materials to setup and produce, so it’s good to know what you’re getting into. SunDance typically turns pouches in 3-4 weeks from art approval, however we have rush programs for emergency needs. Please reach out to your SunDance representative for more details.

Total Cost of Ownership

Finally, it’s good to consider the total cost of ownership for digitally printed pouches, made domestically in-house in Orlando, Florida. Our eco-friendly printing method, fast turnaround and no plate charges allow our customers to buy on demand. Other printing methods may offer a lower cost per unit, however hidden fees like plates or large minimums often apply. Our method allows you to buy what you need, when you need it so you don’t wind up with inventory and tooling that gets thrown away with a simple ingredient or design change. We look to add value with our methods by reducing your inventory obsolescence, and to help the earth by reducing packaging waste.