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Shaped pouches are flexible packaging containers that stand out with their different shapes and sizes. They are a creative type of pouches that are very popular in various industries. This guide provides more information on forming bags.

1. History of shaped pouches

Shaped pouches date back to the 1960s when a French manufacturer named Louis Doyen discovered them. He first developed the stand-up pouch, which was later reinvented as the demand for forming bags for packaging material continued to grow. These pouches were originally called DoyPacks because of their inventors. Also, the shaped pouches are constantly evolving with the growing creativity of our design team.

2. Different types of shaped pouches in the market

The types of shaped pouches on the market include:

1) Stand-up pouch

These are shaped pouches with flat or gusseted bottoms that stand on their own. They can be made in any shape you choose and are common in the packaging industry due to their flexibility. You don’t need hanging holes with stand-up bags.

2) 3 side sealing

Three-sided seal bags are sealed on three sides and only one side is used for product filling. They are mostly flat in nature so hanging holes can be added for easy display.

3. Unique features of shaped pouches to consider

Some features of shaped pouches include:

1) Shape

The shape is very important for shaped pouches as this feature allows them to fit any product. Shaped pouches can be processed into any shape according to your products and consumer needs. For example, you can make them into car-shaped children’s toys and tube-shaped household items such as toothpaste.

2) Brand Marketing

This is due to the ease of printing on the surface of the forming bag and the unique shape. If shaped pouches are brightly colored and have the right shape and design, they will attract more customers to your product.

3) Barrier properties

Shaped pouches are known for their excellent barrier against external disturbances that can affect product quality. They extend the shelf life of products by protecting them from oxygen, moisture, dust, light, etc.

4) Easy to fill

The shape makes the bag compact so it is easy to fill the product with a machine. Automation makes the process faster.

5) Heat resistance

You can customize shaped pouches that can withstand high temperatures by combining films of materials with excellent heat resistance. This feature allows you to microwave the bag when heating baby food, and even pasteurize certain products such as milk.

4. The benefits of shaped pouches

Some benefits of shape bags include:

• Shaped pouches are customer-centric and thus more attractive and stand out from other types of packaging solutions.
• They offer better marketing solutions because of their unique shape and ease of printing and surface branding.
• These bags are inexpensive to produce due to readily available materials and low energy consumption.
• Shaped pouches with clear windows and aroma valves allow for increased product visibility without opening the bag.
• They have excellent barrier properties against external factors such as light, moisture, oxygen, dust, etc.
• We use recycled materials and renewable energy in the manufacture of our shaped pouches. This greatly reduces the level of harmful carbon released into the environment and is therefore considered environmentally friendly.
• Shaped pouches are easy to fill due to the compactness that comes with the shape.
• They are made in layers of durable high-quality material so they can withstand different external pressures.
• It’s easy to add extra features and customize them to meet your product needs.
• Due to their unique shape, size and design, they are a unique packaging solution.
• Due to its shape, it is easy to handle shaped pouches.
• They are very flexible and can fit into very small spaces on the shelf.
• Shaped pouches can be made to suit a specific theme or occasion, such as Easter, Christmas, Halloween, and more.

5. Limitations of shaped pouches

Shaped pouches have limited filing options. Due to their complex design, they cost more compared to other flexible packaging bags.

6. Factors that determine the price of shaped pouches

1) Dimensions

Larger and thicker shaped pouches cost more than smaller and thinner shaped pouches.

2) Shape/Design

The shape design of the shaped pouch affects the price in terms of complexity. The more complex the shape, the more expensive it is to produce.

3) Use

Shaped pouches for liquid products require additional material reinforcement, so they cost more than bags for solid products.

7. The use of shaped pouches

You can use shaped pouches for any of the following items:

• Packaging of liquid, solid, and semi-solid products.
• Product branding and marketing.
• Promote themed seasons like Easter, Halloween, and Christmas.

8. Value-added characteristics of shaped pouches

You can increase the value of your shaped pouches by requesting additional features such as:

1) Processing

A handle is added to the formed pouch to make it easier and more convenient for consumers to carry the bag. You can define the size and type of handle required for the pouch.

2) Hanging hole

These are primarily mounted on shaped pouches to enhance the presentation of the bag and minimize space occupation. Holes can be designed as round or European.

3) Vents or valves

They are one-way outlets mounted on forming bags to facilitate additional product ventilation, degassing or product aroma.

4) Opening

A shaped pouch with an opening allows for quick and easy opening by hand without accidental spills. We add them by pre-cutting one end of the forming bag to guide the consumer.

5) Surface treatment

Shaped pouches are available in two finishing options: glossy and matte. Each has unique qualities, so use them according to your product requirements and consumer preferences.

6) Clear window

This is an important additional feature as it increases product visibility and gives consumers a real feel for the product. They come in various shapes such as oval, round, triangular and square.

7) Fillet

We achieve this by expertly cutting the sharp edges in a curved fashion. This prevents injuries from puncturing with sharp corners.

8) Resealable zipper

The reclosable zippers are a pair of plastic zippers that fit near the edge of the shaped pouch and close with an interlock. They prevent product spills and disturbances from external elements and make the bags reusable.

9) Spout

These tubes fit into the tip of the shaped pouch, making it easier for you to dispense the product. They are mostly packed in shaped pouches containing beverages, juices, alcohol and other liquid products. The pouches are also resealable after opening.

9. Finishing options for shaped pouches

You may consider any of the following finishing options:

1) Glossy

The glossy finish shines, allowing the molded pouch to reflect light on sunny days. It’s a high-quality finish that shows off the print well and makes the pouch stand out. In addition, they are waterproof and suitable for packaging products that do not require any moisture contact. The downside of the glossy finish is that fingerprints can linger on the bag.

2) Matte

This is a non-reflective finish that prevents light from reflecting off the forming bag. This method of bag finishing gives a professional look to shaped pouches. Plus, the font on this bag is easy to read and is a less expensive option. The disadvantage of this method is that it is usually monotonous and cannot be used when printing small fonts.

10. How to fill and seal shaped pouches?

Filling and sealing of formed pouches can be done automatically using a filling machine or manually. It depends on the size of the product you want to pack.

1) Machine filling

Medium and large packaging industries prefer to use automatic filling and sealing machines to make formed pouches. Not only is this faster and more cost-effective, but it also ensures uniform product weight across all bags. Additionally, products that require the complete removal of oxygen from the bag can only be packaged using machines.

• The shaped pouches are loaded into the filling machine with the top open.
• A rotating conveyor belt takes them to the filling area, where a certain amount of product is placed into bags.
• After being loaded into the forming bag, they move to the sealing area according to the sealing method.
• The heat sealer sandwiches the two mouths of the bag between them and heat seals the film layers. Apply moderate heat to avoid melting the material film.

2) Manual filling

This is ideal if you are packaging products on a small scale.

• You need to open the forming bag and fill your product by scooping or pouring liquid product.
• Weigh the filled shape bag on a scale until the desired weight is reached.
• Take out the filled-shaped pouch and seal accordingly using a zipper, heat sealer, screw cap, etc.
• Before sending the packaged bag to the customer, double-check that the seal is secure.

11. Method of obtaining the contents of the shaped pouch

1) Zipper lock

These are the plastic tracks that allow you to close the forming bag by interlocking. They are supplied in pairs and mostly mounted on or near the top of the forming bag. The benefit of using a zip lock in your shaping pouch is the ability to reseal the pouch after opening it. Some customers have gone green and find resealable bags more attractive and convenient

2) Spout

It is the short tube secured to the mouth of the forming bag to aid in dispensing the product. They have a screw cap for easy opening and closing of the forming bags. Additionally, they are commonly used in baby food packaging, juices and purees.

3) Sprayer

This type of closure is found in shaped pouches used to package liquid chemicals such as herbicides and cleaners. It is very convenient and smooth to dispense products with them.

4) Opening

Pre-cut lines along the edge of the forming bag to make opening the bag easier. Shaped pouches using this closure method are disposable bags.

12. How to make shaped pouches?

The manufacture of shaped pouches involves the following key processes:

• Shaped pouches are made by laminating films of different materials using adhesive materials.
• Next, the pouch design is precisely cut out in the desired shape using a die-cutting technology machine.
• Finally, the resulting pouch is sealed and ready for filling.

13. How to detect the quality of shaped pouches?

We have advanced equipment to test the quality of shaped pouches, namely:

1) Thickness

We use the octagon to check whether the thickness of the bag is within limits. Readings are taken along the width.

2) Barrier strength

The barrier of the bags to oxygen, moisture, etc. is done using machines that check moisture and oxygen thresholds. Anything above the set threshold is an indication of poor bag quality.

3) Melt index

Important for heat-sealed shaped pouches to prevent melting while sealing.

4) Dart impact

This demonstrates the burst strength of the formed pouch under pressure.

14. Comparison of shaped pouches and plastic containers

• Shaped pouches are very flexible and can fit into limited spaces, while plastic containers are rigid and take up a lot of space.
• While shaped pouches are less expensive to ship due to their lightweight, plastic containers are heavy and cost more to ship.
• Shaped pouches are made of laminated films of material, while plastic containers are made of one material.
• Preshaped pouches are highly recyclable, while plastic containers emit harmful carbon fumes when burned.
• Shaped pouches cost less than plastic containers because they are less expensive to produce compared to plastic containers.
• Both shaped pouches and plastic containers provide a good barrier against moisture, odor, light and oxygen.
• Plastic containers and pouches can be made in a variety of shapes.

15. Shaped pouches in available sizes

We manufacture bags in all shapes and sizes, small, medium, large and extra-large. We define dimensions for length, width and height. The smallest bags range from 3mm x 3mm x 3mm and the largest bags can be 45 x 35 x 30 inches.

16. The best material for making shaped pouches

The best materials for making shaped pouches should be approved by the safety standards of the US Food and Drug Administration (FDA). They should also be Bisphenol A (BPA) free. These materials are of high quality and are laminated according to the product requirements.
Some of the best forming bag materials are:

• Polyethylene (PE) is a plastic polymer with good heat resistance. It is mostly used for lining, which is convenient for heat sealing.
• Polyethylene terephthalate (PET) is a plastic polymer with excellent moisture resistance. It is also transparent which is perfect for a shaped sachet.
• Aluminum foil (AL) is excellent at preventing odors, moisture and oxygen. They are widely used in the food industry because of their ability to keep food fresh for a long time.
• Kraft paper is usually brown or white, made of wood fibers, and has strong tensile strength.
• Biaxial polypropylene (BOPP) has better heat resistance and is lightweight and transparent. This increases the visibility of the product.

17. Color selection of shaped pouches

We offer shaped pouches in different colors, such as light, dark, mixed, or monochrome combinations. You can choose up to ten color options for your forming bags and we’ll print them for you.

18. Comparison between shaped pouches and packaging films

Shaped pouches adopt different shapes, while packaging films are invisible and adopt the shape of the packaged product. In addition, the forming bag is sealed and only one end is open for product loading, while the packaging film is open. Both are made of the same material structure.

19. Shaped pouch quality certification

Shaped pouches are subject to quality control measures to determine whether they meet safety and health standards. The certificates that shape the packaging bag inspection awards include FDA, EC/CE, SGS, ROHS, ISO, QS, etc.

20. Recommended thickness for shaped pouches

The thickness of the shaped pouch will be determined by the product to be packaged. A thickness range of 2 to 7.5 millimeters (mm) is available.

21. Printing options for shaped pouches

Printed-shaped pouches help convey product information and brand your product in a way that makes it stand out. There are different types of printing options to choose from.

1) Digital printing

Digital printing Prints images from a computer using a digital printing press and the CYMK color combination of cyan, magenta, yellow, and black. This is a fast, precise, and clean printing method recommended for small print jobs.

2) Flexographic printing

This form of printing method uses a rotating plate to transfer the print onto the surface of the bag. The raised areas of the plate collect the ink, and a squeegee is used to expel excess ink before printing on the pouch. It is ideal for high-quality printing of large volumes of shaped pouches.

3) Gravure printing

The gravure printing method caters to shaped pouches that cannot be printed by flexographic printing. This is a high-speed machine printing that uses a metal roller to engrave the print on the shaped pouch. The metal engraving cylinder is filled with ink, drains excess ink, and then impresses the image or print on the surface of the bag. It provides high-quality prints without print spillage.

22. Application of shaped pouch with valve

A valve is a one-way vent that is fitted to a forming bag for a variety of reasons, such as:

• The valve is installed in the forming bag used to pack the coffee beans to release excess gas to avoid pressure build-up. This helps maintain product freshness.
• They also act as an aroma outlet for certain products, allowing consumers to smell the product without opening the package.
• Valves are also used to provide product ventilation, which enhances air circulation in the bag, thereby extending product shelf life. The size of the orifice depends on your product requirements and the type of material used.

23. Products that can be packed in shaped pouches

Shaped pouches can be used to pack edible or inedible solid and liquid products. The product range includes:

• juice
• water
• yogurt
• baby food
• puree
• butter
• cream
• dressing
• vinegar
• coffee beans
• alcoholic beverages
• gel
• handwashing fluid
• shampoo
• lotion
• oil
• hand soap
• detergent
• lubricating oil

24. Available pouch shapes

We offer bags in different shapes, such as:

• A jar pouch is a stable pouch that can stand on its own. Plus, they feature a traditional jar shape with a zipper as a closure option. Thanks to the large opening, they can be filled easily and quickly.
• Tree pouches are common around Christmas to help sell different gifts for the season. Plus, they’re brightly colored and attractive with various Christmas messages printed on them.
• Bottle-shaped pouches are designed in different bottle shapes, such as wine bottles, beer bottles, etc. These bags are commonly used to package alcoholic beverages, water, cooking oil, juices, and fruit puree.
• Heart bags are perfect for when you’re targeting special occasions like lovebirds and Valentine’s Day. In addition, these bags are mostly used for packaging chocolates, candies, teddy bears, etc., and are available in bright and attractive colors such as red, purple, and pink.
• Hourglass pouch
• Convex bag

25. Material structure of shaped pouches

Depending on your product needs, different bags may have different structures. Each material structure has unique properties that make it ideal for use in forming bags. We determine the material structure combination and thickness according to your product requirements.
Other structures may include:

• PET/aluminum foil/poly
• PET/poly
• PET / MET PET / POLY

Aluminum foil is very useful in providing an oxygen and water vapor barrier.

26. How to choose barrier material for shaped pouches?

When selecting a barrier material for your product, we consider the following factors:

• Product requirements, such as blocking environmental factors such as oxygen, moisture, and odor.
• The material thickness will allow us to manufacture shaped pouches with the desired barrier qualities.
• The use of formed pouches such as microwavable, boilable, and freezable is determined by the choice of material.
• With high mechanical strength, stiffness, and punch resistance, shaped pouches are made of polymer.

In short, by considering all these, you will surely get high-quality and reliable shaped pouches.
Please do not hesitate to contact us if you have any questions.

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