PRODUCT DICTATES POUCH
Plastic pouch converters market their malleability in packaging a vast array
of products.
by Jessica Millward, Associate Editor
CUSTOM CONVERTING HAS become a way of life for printers, with product manufacturers exhibiting a more developed interest in and knowledge of packaging processes. The latest breed of plastic pouches necessitates client involvement—the nature of the product and its packaged "life cycle" can determine both substrate and construction.
Design process
While the burgeoning popularity of pouches, particularly stand-up varieties, has translated into some semi-standardized constructions, design is typically a collaborative process.
Pechiney Plastic Packaging Marketing Manager, Dry Foods, Law Burks attests, at a minimum, pouch customers detail barrier needs; stiffness requirements; preferred substrates; size/volume considerations; and print method (surface or reverse, gravure or flexo) before choosing a pouch design.
At converter Specialty Films & Associates (SF&A), the exchange of information is vital. President Jane Dirr emphasizes SF&A requires, "a clear understanding of the product being packaged, [awareness] of specific shelf life requirements, environmental concerns for storage/shipping, and the anticipated use that the pouch needs to withstand."
The open-exchange approach served SF&A well in creating a stand-up pouch for M•A•C Cosmetics' reformulated Pro Lash mascara (previously housed in a folding carton). M•A•C's Package Development Group had fairly specific requests regarding the pouch's construction and appearance. To replicate the company's signature gunmetal color, M•A•C wanted a two-sheet film construction—a sheer gray front and a darker gray back—with printing ability on both sides. "Everyone else wanted to print the front and label the back, but that's not where we wanted to go," explains Package Development Group Director Peter Rizzo.
Dirr affirms the importance of color in cosmetics, and notes the film structure of the mascara pouch therefore took months to perfect. "There are cases where the client already knows the films they want to use. However, we find it beneficial to still investigate alternatives that perhaps can provide cost savings, better barriers, or other features that the client might not be aware of," she states.
Design features
Sealing and dispensing functions have proved to be the latest focus of the plastic pouch's evolution. Recognizing a need in the pet food market for a flexible pouch that can be stacked and palletized easily, Pechiney recently announced it would introduce a four-side-seal bag. The package structure makes printing on all sides possible, and lends the pouch stand-alone ability. Sealing options include a press-to-close feature or a slider zipper.
Zipper constructions abound in new pouch designs as well. For example, SF&A employs its Mini-Grip Slider zipper, while LPS Industries manufactures the Top-Loc® zipper in clear, colored, or anti-static varieties.
Spouts, too, have become more efficient and popular in plastic pouch construction. Kapak Corp. paired with Seaquist Closures to incorporate the latter's SimpliSqueeze® dispensing technology into flexible pouches for food, health/beauty, and other applications. In the beverage industry, the SmartSpout is being positioned as an alternative to single-serve polyethylene terephthalate bottles.
The dispenser assembly uses a three-piece design, consisting of a polypropylene overcap, a polypropylene base fitment with a spout, and a silicone valve. The system enables dispensing in two ways—the pouch can be squeezed to empty the product through the spout, or the consumer can place their lips around the spout and draw the liquid up through the valve.
In addition to closure systems, Pechiney Senior R&D Engineer Cori Kohl and Research Associate Dan Brewer have witnessed an increased demand in stiffer sealants for down-gauging purposes, as well as the growth of the contour pouch. Recent print trends they have noticed include scented varnishes or inks, thermochromatic inks, and holograms.
Dirr says SF&A has teamed with substrate suppliers in utilizing deep-dyed, partially metallized films for high-end cosmetic applications. Market-wise, SF&A has a strong base in spouted pouches, and manufactures custom-shaped packaging.
