Laminated Pouches: Everything You Need to Know

Laminated pouches are a flexible packaging solution made by bonding films of different materials using adhesives. They have excellent barrier properties and are a versatile packaging solution. This guide explores their different shapes, designs, colors, sizes, materials, and closure options.

1. Types of laminated pouches on the market

Types of laminated pouches on the market There are six of them：

1) Flat laminated pouch

These laminated pouches are flat on both sides and there are no gussets or creases in any part. They mostly have economical dimensions and are bottom or side sealed. In addition, they are commonly used in the food and non-food industries for packaging confectionery, beauty products, medical products, etc.

2) Gusseted laminated pouches

The gusset is an extension material that, when added, increases the reinforcement or volumetric capacity of the bag when filling. When placed at the bottom, it provides extra strength to the bags, so they can stand independently. Compared to normally laminated pouches, side gussets provide more space for laminated pouches and increase their capacity. They are mainly used to package beverages such as tea and coffee.

3) Self-standing laminated pouches

These are laminated pouches capable of standing upright on their own on any flat surface. This is because their bottom is flat or gusset, and most of them flatten in a “W” shape when opened. Due to their versatility, they are the most common type of laminated pouch on the market. Stand-up laminated pouches can be used for food and non-food products such as snacks, pet food, toys, medicines, etc.

4) Laminated pouch with the mouthpiece

These types of laminated pouches have a tube fixed to the top with a lid on top for closing and reclosing the bag. The nozzle makes it easy to dispense and refill laminated pouches, and spillage can also be controlled. Due to their flexible design and the presence of nozzles, they are an alternative to plastic and glass bottles. Therefore, they are often used to package liquid products such as sauces, cooking oils, liquid soaps, juices, etc.

5) Special-shaped laminated pouches

Profiled laminated pouches are flexible pouch design that is available in a variety of sizes and shapes. You can customize the shape and design of your laminated pouch, such as dolls, bottles, rectangles, circles, etc. This creative form of laminated pouches is popular in the food and beverage industry.

6) Laminated pouch with zipper

Laminated pouches with zippers feature a reclosable zipper as a closure option. The zippers are a pair of plastic structures that are fixed on both sides of the pouch near the top and closed by an interlock. They help prevent unwanted contents from spilling when the bag is closed and facilitate the resealing of the bag.

2. Benefits of reusable laminated pouches

Reusable laminated pouches can be washed, dried, and reused many times, provided they are kept in good condition. Some of the benefits are:

Reusable laminated pouches are cost-effective because they eliminate the recurring cost of each laminated pouch
They are eco-friendly because they reduce the amount of packaging material discarded after one-time use.
They are durable, so they can extend the shelf life of the product.

3. Advantages of reusable laminated pouches

Reusable laminate pouches have strong tensile strength, so they provide extra protection for your products.
They are simple and convenient to use as they have resealable zippers or nozzles as closing options.
They are attractive to customers who value recycling and support green packaging.

4. How to close laminated pouches

There are three ways to close：

1) Zipper

Zippers can open, close, and reopen laminated pouches by moving them from one end to the other. Depending on your choice and product type, they come in a variety of designs. They make laminated pouches reusable.

2) Spouts

These are tubes that protrude from the top of the laminated pouch with nut caps for opening and closing. They make filling and dispensing of laminated pouch contents easy.

3) Heat sealing

Heat sealing is common in disposable laminated pouches sealed using a heat sealer. They provide a tight seal for your product and open it by pulling the seal open.

5. Disadvantages of laminated pouches

Laminated pouches cannot be microwaved because they can easily catch fire.
They are mostly opaque, so customers can’t see the content without opening it.

6. Comparison of laminated pouches with other packaging solutions

Laminated pouches are flexible, so they can fit into smaller spaces compared to other rigid packaging solutions such as plastic and glass.
Laminated pouches are cheaper to produce compared to other packaging solutions because they consume less energy and raw materials are cheaper.
Laminated pouches provide a better surface for printing compared to other packaging solutions, making branding easier and more convenient.
Compared to other packaging solutions that can be fragile, laminated pouches are durable, so they can extend the shelf life of the product.
Laminated pouches are easy to handle because they are not slippery and some also have handles. Due to the smooth surface, other packaging solutions can be difficult to handle without handles.
Laminated pouches increase the freshness of the product due to their internal aluminum foil and valves for venting unwanted gases. Other packaging solutions are airtight, so odor residues can result, affecting product quality.
Laminated pouches are lightweight, so they are more economical to transport compared to other packaging solutions that tend to be heavy.
Laminated pouches break down naturally, so they don’t end up piling up in landfills, reducing environmental waste. Other packaging solutions, such as glass or plastic containers, cannot break down and therefore end up in landfills and reservoirs.
Solid, liquid and even frozen products can be packaged in laminated pouches. Product-specific packaging solutions cannot be interchanged with other packaging solutions.
Both can be reused if properly cleaned and dried after initial use.
Both have good barrier properties against oxygen, moisture, dust, bacteria, etc.

7. Features of laminated pouches

Laminated pouches have excellent barrier properties against external factors such as oxygen, steam, and bacteria.
They do not contain BPA and are FDA approved.
They are lightweight, easy to carry, and also reduce shipping costs.
They can be customized into different shapes, designs, colors, and materials.
They can add extra features like tear notches, zip locks, hanging holes, handles, etc. to improve them.

8. Comparison of laminated pouches vs plastic bags

Some of the main features of laminated pouches and plastic bags:

Laminated pouches have excellent barrier properties due to the additional material film, while plastic bags do not have an additional material layer.
Laminated pouches can pack solid, liquid, or even frozen products, while plastic bags are not suitable for liquid and frozen products.
Laminated pouches are odorless due to their resistance to bacterial invasion, while plastic bags are susceptible to bacterial attack.
Both are light and portable, so shipping costs are reduced.
Both offer flexible packaging solutions for a variety of products.

9. The best material for laminated pouches

Depending on the products you package and your preferences, we offer a variety of high-quality materials for the manufacture of laminated pouches. Our materials are quality-tested, BPA-free, and meet U.S. Food and Drug Administration (FDA) standards.

Some of the best materials we have are:

Cast polypropylene (CPP): Mainly used as an alternative to polyvinyl chloride (PVC) film. It is transparent, impact resistant has good temperature resistance, and has a smooth surface. It is very versatile and mainly used for packaging food and non-food products.
Aluminum foil: This material is widely used in the food industry due to its excellent barrier to oxygen, light, moisture, and bacteria. They are also cheap compared to other material types. It is very good at preserving the original flavor of food, thus maintaining the freshness of food for a long time.
Polyethylene terephthalate (PET): is a thermoplastic polymer resin widely used in the manufacture of flexible bags. This material has excellent waterproof barrier properties and a clear appearance. It can be made in combination with a biaxially oriented film (MPET), making it opaque and reflective. It can be wrapped in a film of other materials to make it less prone to punctures.
Metalized PET: Aluminum powder is plated on plastic film such as PET. This makes PET material more tear-resistant, lighter, and more flexible, and prolongs product freshness but not airtight.
Polypropylene (PP): Like PET, this is a thermoplastic polymer resin. It is superior to PET film in terms of heat resistance and mechanical strength.
Kraft paper: Available in brown or white, it has a high tensile strength due to the wood fiber. They can be well coated with PE film materials to achieve good barrier properties.

These materials have different desirable properties, and combining them makes high-quality bags.

10. Available color options for laminated pouches

Depending on your preferences and product needs, laminated pouches are available in single or multiple colors, even in transparent form. If you specify in your order, we can provide up to ten color options for your laminated pouch order. We use four colors; Cyan, magenta, yellow, and black (CMYK) or Pantone scheme methods print colors.

11. Common defects in the sealing process of laminated pouches

Here are some common pitfalls of laminated pouches:

1) Compression seal

A compression seal occurs due to overheating of the sealing area, which breaks the seal.

2) Fold the stamp

Occurs when a layer of film in the sealed area is not evenly unfolded, resulting in folding.

3) Swollen seal

An expanded seal is a bulge of a seal caused when the material wire is cut off. This can trap gases or lead to the build-up of microorganisms in the seal.

4) Contaminated sealing

This is a type of seal in which unwanted materials are embedded that may affect the quality of the packaged product.

5) Cracked seals

This seal is not perfect and may have punctures or tears in one or different layers.

12. How to check the quality of laminated pouches

Mainly from the following four aspects：

1) Sealing strength

We use a universal testing machine to check the integrity of the heat seal by applying a tensile force to the seal. Weak seals can burst with a light pull, while strong and high-quality seals can withstand a period of pulling force.

2) Impact test

We perform a drop test to check the drop resistance after the laminated pouch is packed.

3) Bond strength

This is essential to check that the laminate has been well glued into one unit. The same seal testing machine is used to confirm this characteristic.

4) Barrier test

Barriers against external factors, such as oxygen and vapor transfer rates, are completed to ensure that they remain within permissible thresholds. As a result, product quality and shelf life are directly affected.

13. Available size options for laminated pouches

We offer laminated pouches in different sizes, including ready-made and customized orders. Dimensional dimensions are width, length, and thickness, and thickness is measured in “inches”. The thickness depends on the type of product you intend to pack and the barrier performance you want to achieve. Our small laminated pouches measure 50 x 70 millimeters (mm) and have a maximum size of 350 x 600 mm. We can customize your laminated pouch according to your size specifications.

14. Common applications of laminated pouches

Laminated pouches are very flexible and versatile packaging solutions that can be used in a variety of areas:

Food packaging such as snacks, candy, pet food, cereals, frozen fish, beverages, juices, and baby food
Fresh produce such as green beans, bell peppers, tomatoes and spinach
Agricultural products including seeds, fertilizers, herbicides, and pesticides
Medical products: bandages, medicines, syringes
Pharmaceuticals such as antibiotics, painkillers, and nutritional supplements
Body lotion, hand cream, shampoo, conditioner, and other beauty products
Other industrial packaging includes toys, electronics, chemicals, deep groove ball bearings, coal, etc.

15. The reason why laminated pouches have no peculiar smell

The inner lining of the laminated pouch is aluminum foil, which has excellent barrier properties against bacteria, oxygen and moisture. This makes the bag resistant to attacks by external factors that cause the product to degrade and produce odors.

16. Safety features of laminated pouches

Security features are in place to protect your products from accidental tampering while in transit or on the shelf. Some of the security features include:

1) Tear notch

These serve as a security feature where you can know when the laminated pouches of your package have been tampered with. Once you tear the notch, it is impossible to reclose the pouch.

2) Clear window

You can secure the laminated pouch to a transparent window on one or both sides of it. In addition, to improve the visibility of the content, they also allow you to notice if the contents of the bag have been dug up.

3) Rounded corners

Some laminated pouches have sharp corners when they are cut during the manufacturing process. Sharp corners can easily cause harm to anyone who touches laminated pouches, especially younger consumers. To prevent such injuries, we recommend using rounded corners that are harmless to the end user of the bag.

4) Handles

Handles can be added to laminated pouches for easier management of the bags. They make it easy to carry the pouch, preventing accidental drops that can lead to spillage of the product.

5) Valves

Also known as ventilation holes, it is common in beverage packaging, especially roasted coffee beans. They help release excess carbon dioxide gas (CO2) emitted by roasted coffee beans. The valve prevents pressure build-up that can cause the laminated pouch to burst.

17. Printing process of laminated pouches

You can print laminated pouches to add company logos, brand your products, and deliver product information and instructions. Some of the printing techniques we use are: Shrink sleeves are the perfect solution for taking your product’s appeal to the next level.

1) Gravure printing

This technique uses a rotating metal cylinder with a pattern engraved on the surface. Patterns come in different depths depending on the color intensity you need on your print. These patterns are created on the surface of a metal cylinder using acid corrosion. As the roller rotates, the pattern collects ink from the cartridge and then drains the excess ink before transferring the print. When the patterned roller rotates, the second roller “imprint roller” moves the bag to the patterned roller for direct printing. After that, it moves forward to the next roller to get a different color or exit the process. Gravure printing is a high-quality professional printing process that is ideal for high-volume printing, but it is costly. It is printed using CMYK color or Pantone color.

2) Flexographic printing

Flexographic printing, also known as “flexography”, is a printing method that uses a plate on a roller to transfer the printed matter to a bag. The surface of these plates has raised areas that fill with ink when the roller rotates. The rotating squeegee drains excess ink from the plate before transferring it to the pouch. It is a high-speed technology, so it is a great solution for large-volume pouch printing. It uses CMYK or standard Pantone color schemes in printing.

3) Digital printing

This method uses a digital printing press and computer to print an image, logo, or text on a laminated pouch. Apply CMYK during this process to achieve the printing you need. The advantages of digital printing are fast speed and short turnaround time, so it is ideal for small orders. In addition, the print dries immediately and there is no need to change or adjust the printer for the next print job.

4) Hot/cold stamping

This printing solution uses hot or cold foil to print the metallic color of your choice, mainly silver or gold. Hot stamping uses a heated foil to press the image to be printed, while cold stamping presses an adhesive foil. The printed image left behind is clean and leaves no traces, making your pouch look luxurious.

18. Common surface treatment options available for laminated pouches

We apply surface treatment to change the surface of the laminated pouch to achieve specific properties.

1) Matte treatment

This type of finish is dull, rough, and non-reflective and retains the original color of the laminated pouch. It gives your laminated pouch a professional impression. One of the advantages of applying a matte finish is that it does not blind you or your clients in the sun. Fonts on matte surfaces are also easier to read than glossy fonts and are also a cheaper processing option. The disadvantage of the matte finish treatment is that it makes printed graphics look dull. Without a protective cover, it is also easily damaged by corrosion and makes it difficult to read small prints.

2) Gloss Finishing

Unlike matte, this finish gives your laminated pouch a gorgeous, smooth, and eye-catching finish. It is ideal for high-quality and color-printed laminated pouches as it can make graphics stand out. The good thing about using glossy finishing is that it helps to promote new products in the market in an eye-catching way. It also makes the laminated pouch waterproof, which enhances its moisture resistance.

In addition, the glossy finish is shiny and clean, and uses high-quality materials, making colored artwork very popular. This naturally attracts consumers to buy your products, which drives up your sales. The disadvantage of using a glossy finish is that it is very reflective in sunlight, so it creates a blinding effect. It is also easy to get dirty because it leaves marks and fingerprints on the laminated pouch.

19. Factors to consider when importing laminated pouches

1) Import costs

The total cost of buying and importing laminated pouches shouldn’t be so high that you can paralyze your operations. This includes taxes, import duties, and shipping costs.

2) Product reviews

It’s important to check product feedback from previous customers to help you make an informed decision.

3) Delivery time

This is important, especially when importing fast-moving products, and you should place your order on time.

20. Quality certificate

We comply with standard procedures for food and health safety, environmental safety, good manufacturing practices, labor law, etc. As a result, we have obtained many certificates such as FDA, ISO, SGS, CE/EC, ROHS, TUV QS, and many others. For all your laminated pouch needs, you can contact us now.