Considerations In Moving From Rigid To Flexible Sleeve Packaging

 In many different industries, there is a packaging shift taking place. From foods and beverages to laundry detergents, household items, soaps, shampoos, pet foods and even pharmaceuticals, more and more companies are moving from rigid packages and containers to flexible packaging such as pouches and bags. This type of change effects not only the company doing the packaging, but the entire packaging industry itself, as such a shift means new methods of packaging products, new machinery and new processes.

The shift to such Sleeve Packaging stems from several different advantages offered by pouches, bags and other flexible containers. For customizing packages, items such as pouches make unique shapes and sizes much easier to fabricate and repeat with consistency. In addition, where rigid containers normally have a small area or a labeled area for logos, photos, information or decoration, pouches and other flexible packages allow the freedom to use the entire container for the same purpose, generally giving packagers more creative freedom. Such packaging can also be more resilient than rigid containers, surviving drops and other impacts more frequently without the damage that leads to lost product, refunds or returned products. As for bottom line, a move to flexible packaging can mean lower energy and shipping costs as well. Using less material in and of itself means using less energy, and compact flexible packaging takes up less space when shipping than the rigid counterparts. These two examples also contribute to the fact that flexible packaging is simply a more environmentally friendly, or green, alternative. Less energy and less material equals less waste. For each individual packager one or all of these motives may push a business to move from rigid containers to flexible packaging.

But for those currently using rigid containers, the move to flexible packaging can mean doing a lot more than simply switching containers. Packaging machinery built for rigid bottles and other container types may not allow for an easy switch to pouches or bags. At the very least, some modification may be necessary, and at worst, a completely new packaging line might be required. For those using machinery for lower production runs, semi-automatic equipment may be easier modified than completely automated packaging systems. Generally, semi-automatic equipment will be activated by a foot or finger switch for filling, sealing or other packaging processes. The key to modifying such machines for flexible packaging will normally lie in stabilizing and positioning the package and, in some cases, opening it for the introduction of product. When dealing with turnkey, automated packaging systems, not only must each machine be modified to handle the package, but the transfer system, typically power conveyors, must also be modified or converted. In some cases, the expense of converting such a system may cost a company as much, or more, than purchasing new equipment specifically for pouches, bags and other flexible packages.

The best course of action to take when considering a switch from rigid to flexible packaging is to include your packaging machinery manufacturer from the outset. With numerous options available for flexible packaging, the manufacturers can provide insight as to the required modifications, additions or purchases that will be necessary for each and every package considered. Waiting to involve the manufacturer until after the package choice has been made can lead to extra time and expense that could have been avoided by simply asking for input at the beginning of the process. And sometimes simple changes to packages, closures or other components can make a huge difference in the machinery required, without compromising the vision of the packager.