Materials & printing
Flexible Packaging Materials & Printing
We produce custom printed pouches and bags using different material structures, barrier levels and printing technologies. From short digital runs with multiple designs to larger-volume flexographic and rotogravure production.
Choosing a structure
The right material depends on what you are packing
There is no single material structure that works for every product. Shelf life, moisture, oxygen, light, aroma, pouch size, filling process and recycling requirements can all affect the right choice.
Tell us what you are packing and we can recommend a suitable structure.
- Shelf life
- Moisture
- Oxygen
- Light
- Aroma
- Pouch size
- Filling process
- Recycling requirements
Packaging materials
Material structures for flexible packaging
Most printed pouches are laminated packaging, made from two or more films bonded together. These are the main material families we work with.
High-barrier laminates
PET / metPET / PE or BOPP / PET / ALU / PE
Multi-layer structures designed to provide strong protection against moisture, oxygen, light and aroma loss.
Often used for: coffee, supplements, spices, pet treats, hiking foods and other shelf-life-sensitive products.
Clear laminates
PET / PE
Versatile structures for products that need good protection without an opaque metallized barrier layer. Clear windows can also be incorporated into many pouch designs.
Often used for: snacks, tea, powders and dry foods.
Mono-material options
Mono PE / Mono PP
Mono-material structures are available for projects where improved recyclability is an important requirement. Barrier layers such as EVOH may be used where appropriate.
Designed for improved recyclability. Recyclable where suitable collection and recycling streams exist.
Often used for: pet food, supplements, dry foods and refill packaging.
Kraft & paper-look options
Natural appearance, modern barrier performance
Kraft and paper-look finishes can give packaging a natural appearance while using a functional inner structure selected for the product.
Often used for: coffee, tea, snacks and premium natural products.
Compare common material structures
| Structure | Main advantage | Typical applications |
|---|---|---|
| PET / PE | Versatile clear laminate | Snacks, tea, powders |
| PET / metPET / PE | High barrier and light protection | Coffee, supplements, spices |
| BOPP / PET / ALU / PE | High barrier with aluminium foil layer | Hiking foods |
| Mono PE | Mono-material option | Pet food, supplements, refill packs |
| Mono PP | Mono-material option with different stiffness and heat properties | Selected food and non-food applications |
| Kraft-based structures | Natural look | Coffee, tea, snacks |
The final structure and thickness depend on the product, filling process, shelf-life requirements and pouch format.
Pouch printing
Printing for both short and large production runs
We are not limited to one printing technology. The right printing method depends mainly on order quantity, number of designs, artwork and repeat volumes.
| Digital printing | Flexographic printing | Rotogravure printing | |
|---|---|---|---|
| Best for | Small to medium runs | Medium to large runs | Large runs |
| Typical setup | No traditional printing plates | Printing plates | Engraved cylinders |
| Multiple SKUs | Excellent | Possible | Possible |
| Short runs | Excellent | Less economical | Usually not economical |
| Large runs | Possible, but not always the most economical | Very good | Excellent |
| Main advantage | Flexibility | Scale efficiency | High-volume consistency |
| Typical use | Launches, many designs, smaller orders | Growing repeat products | High-volume, established products |
Digital Printing
- Best for
- Small and medium quantities
- MOQ
- From approximately 500 pcs, depending on specification
- Strength
- Multiple designs and SKUs without traditional printing plates
- Good choice for
- New product launches, seasonal packaging, testing and brands with many SKUs
We use high-quality digital printing, including HP Indigo technology, for flexible packaging projects where flexibility and shorter production runs matter.
Flexographic Printing
- Best for
- Medium and larger quantities
- Setup
- Printing plates are required
- Strength
- Efficient production at higher volumes
- Good choice for
- Established products with repeat orders and larger quantities
Flexographic printing becomes increasingly cost-efficient as production volumes rise.
Rotogravure Printing
- Best for
- Large quantities
- Setup
- Engraved cylinders are required
- Strength
- Consistent premium print quality across high-volume runs
- Good choice for
- High-volume products and long-running packaging designs
The higher initial setup cost can be offset by competitive unit pricing on large production runs.
Not sure which printing method makes sense?
Send us your pouch size, quantity and number of designs. We can compare the suitable production options for your project.
Production
How a printed pouch is made
- 01
Printing
Your artwork is printed onto the packaging film using the selected printing technology.
- 02
Lamination
Different film layers are bonded together to create the required appearance, strength, barrier and sealing properties.
- 03
Curing & slitting
The laminated material is cured where required and cut into rolls suitable for pouch production.
- 04
Pouch conversion
The laminated film is formed into the selected pouch or bag format. Zippers, valves, spouts and other features can be added.
- 05
Quality control & delivery
Finished packaging is inspected, packed and prepared for delivery.
Laminated packaging
Why flexible packaging uses multiple layers
A printed pouch can combine several films because each layer performs a different job.
In mono-material structures, the layers are based on the same material family, such as PE or PP.
Outer layer
Print quality, appearance and surface protection
Barrier layer
Helps protect against oxygen, moisture, light or aroma loss
Inner sealing layer
Provides the heat-seal surface and direct product-contact layer
Product side
Options
Pouch features
Add the closures and details your product needs. See all pouch and bag formats on our Products page.
Standard zipper
Resealable closure for repeated use.
Pocket zipper
Premium front-opening zipper option.
One-way degassing valve
Commonly used for freshly roasted coffee.
Tear notch
Easier opening.
Euro hole
Hanging retail display.
Spout & cap
For liquids and refill packaging.
Clear window
Lets customers see the product.
Custom dimensions
Dimensions can be adapted to the product and filling requirements.
Finishes
Printing finishes
Matte
Soft, premium appearance.
Glossy
Brighter colours and stronger shine.
Metallic
Metallic visual effects using suitable film structures.
Sandpaper touch
Rough, textured surface you can feel in the hand.
Industries
Different products need different packaging
Specifications are selected project by project
Film thickness, layer structure, barrier level, sealing requirements and production tolerances vary depending on the product and application. We provide the appropriate technical specification when quoting your project.
Get free samples and a quote.
Tell us what you are packing, the pouch or bag format you need and your approximate quantity. We’ll come back with pricing, a material recommendation and free samples.