SKLUBS flexible packaging

Custom printed pouches for UK brands

Start with the product, its measured fill volume and its target shelf life. Then compare pouch formats, film structures and closures. This page helps you narrow down the specification before investing in artwork or tooling, and compares formats for different products.

From 250

Units per design and format; confirmed in your quote

5–7 days

Production after written print-proof approval

Factory direct

Coordinated through our Guangdong office

Custom dimensions

Dimensions developed around your product

Definition

What flexible packaging includes

Flexible packaging uses a film or laminated structure rather than a rigid wall. The same planning questions apply across the range: what the pack must protect, how it will be filled, and how it will be stored and used.

Flexible or rigid: practical differences for a brand

Criterion	Flexible packaging	Rigid packaging
Transport volume	Unfilled packs ship flat and occupy less space	Empty containers occupy their full volume
Storage before filling	Flat storage, with a small footprint	Bulkier storage before filling
Printable surface	Multiple printable panels, depending on the format	Often a label or selected decoration area
Barrier performance	Depends on the film structure	Depends on the container and closure
Production minimum	Depends on the format and printing process	Depends on tooling and decoration
Custom dimensions	May require a dedicated cutting tool	May require a dedicated mould
Shelf presentation	From flat sachets to bags with a stable base	Depends on the container shape

Flexible packaging can reduce the space occupied by unfilled packs and provide a broad printable surface. Choose it around the product and packing process, rather than treating the unit price as the only deciding factor.

SKLUBS flexible packaging, from flat sachets to five-panel flat-bottom bags.

Three decisions to make before choosing the format

Start with target shelf life, measured product volume and quantity per design. Shelf life helps define the barrier structure. Fill volume determines the useful dimensions. Quantity influences the production process and the share of setup costs in each unit.

A pouch can fail before colour becomes an issue: it may be too large because capacity was estimated from weight, offer too little protection for the intended shelf life, or be uneconomical at the selected order quantity.

Use the comparisons below to answer these questions, then develop the selected format in more detail.

Target shelf life helps define the barrier
Measure volume; do not infer it from weight
Quantity per design influences the production model
Choose the format after these requirements are clear

Formats

Pouch formats: how to choose

Formats differ in how they stand, their useful capacity and their printable panels. Film, closure and finish are then selected around the product and manufacturing requirements.

Compare the formats by their practical differences

Format	Stands upright	Typical nominal fill range	Printable panels	Typical use	Guide
Stand-up pouch	Yes, with a bottom gusset	50 g–1 kg	2,5	A versatile starting point for packs that stand upright	Custom stand-up pouches
Flat-bottom bag, five panels	Yes, with a separate flat base	250 g–2 kg	5	Larger fills and a stable shelf footprint	Custom flat-bottom bags
Flat pouch, three sealed sides	No	5–250 g	2	Single doses, samples and inner sachets	Custom food pouches · Custom three-side-seal pouches
Kraft zip pouch	Depends on the construction	50–500 g	2,5	A paper appearance, with the barrier specified separately	Custom kraft zip pouches
Mylar pouch	Depends on the construction	1–500 g	2–2.5	Barrier-led specifications for compact packs	Custom Mylar pouches
Compostable pouch	Depends on the construction	50–500 g	2,5	A specified end-of-life route, supported by relevant evidence	Custom compostable pouches

Compare the filled pouch when deciding between a stand-up pouch and a flat-bottom bag. At larger volumes, the separate base and side panels can improve stability and presentation. Weight alone does not establish the correct pouch size.

Stand-up pouch

A V-shaped bottom gusset, an upright format and an optional zip: a versatile starting point for flexible packaging.

Flat-bottom bag

Five panels, printable side faces and a separate flat base. Validate the filled dimensions and weight for your product.

Flat sachet

Three sealed sides and no standing base. Useful for samples and single doses. Explore the format, closures and finishes in the guide to custom three-side-seal pouches.

Kraft pouches

A paper appearance outside, with the protective film layers specified inside.

By product

Which pouch suits your product?

The product is the starting point because it determines the protection required. Use the rows below to identify a direction for the specification, then confirm it for the actual product and filling process.

The product determines the structure

Product	Main requirement	Formats to consider	Structure	Further reading
Roasted coffee	Gas release and oxygen	Flat-bottom or stand-up pouch, with a valve where required	Metallised film or aluminium foil	Custom coffee packaging
Tea and infusions	Aroma protection and leaf volume	Stand-up pouch sized for the measured volume	An appropriate aroma and moisture barrier	Custom tea packaging
Dry foods and dried fruit	Moisture	Zip stand-up pouch	Metallised film	Custom stand-up pouches
Powders and supplements	Clumping and powder buildup in the zip	Stand-up or flat-bottom pouch	Suitable barrier film and closure profile	Custom zip pouches · Custom protein packaging
Pet food and treats	Fat content and filled bag weight	Stand-up, flat-bottom or gusseted bag	A structure suitable for fatty products	Custom pet-food packaging
Fatty products and coated snacks	Fat migration	Stand-up pouch	An inner layer suitable for fatty products	Custom food pouches
Fast-turnover products	End-of-life route and presentation	Kraft stand-up pouch	Compostable structure with relevant evidence	Custom compostable pouches
Sensitive products in compact packs	Light, oxygen and odours	Mylar pouch	Aluminium foil	Custom Mylar pouches

For food-contact packaging, the shape of the pouch is only one part of the brief. The proposed material must be assessed for the specific food, contact conditions and destination. Request the relevant documentation before approval.

The product determines the structure. Order quantity determines how setup costs are distributed. Resolve both before approving the pack.
The starting point for a flexible-packaging brief

Our first questions concern what you are packing, how long it must keep and under what conditions. An unsuitable barrier can put the product at risk regardless of how attractive the unit price looks.

Develop a specification for your chosen pouch format.

Specify format, fill volume, film, closure and quantity. If two formats remain suitable, ask for like-for-like quotes so you can compare the complete production and delivery terms.

Your quote confirms the minimum for your specification
Custom dimensions and tooling terms are confirmed in the quote
Film layers and thicknesses are specified in the quote

Materials

Film structures and the protection they provide

Film structure determines much of the barrier performance. The comparison below is a starting point, not a shelf-life guarantee. Validate the complete pack with your actual product.

Structures, protection and indicative shelf-life ranges

Structure	Moisture	Oxygen	Light	Indicative shelf life	End of life
Kraft with polyethylene lining	Moderate	Low	Good	6–9 months	Often unsuitable for conventional film recycling; verify the full structure
Mono-material structure	Good	Moderate	Depends on the print and structure	9–12 months	Film collection and processing, where accepted locally
Compostable structure with relevant evidence	Moderate	Low	Good	3–6 months	Specified composting conditions and relevant certification
Metallised film	Very good	Very good	Complete	12–24 months	Often unsuitable for conventional film recycling; verify the full structure
Aluminium foil	Excellent	Excellent	Complete	24 months or more	Often unsuitable for conventional film recycling; verify the full structure

These ranges are indicative and require testing with the actual product. Barrier performance and end of life involve different requirements; no appearance or material name proves either on its own. For products placed on the French market, information on the relevant packaging system is available from Citeo for French-market producer-responsibility requirements. Other markets have their own systems; identify the destination in your brief.

Metallised film and aluminium foil differ

Metallised film uses a thin deposited metal layer. Aluminium foil uses a separate foil layer. Their appearance may be similar, but thickness, barrier performance and cost differ. Compare the complete layer specification.

Recyclable and compostable refer to different routes

Recycling returns material to a processing stream. Composting involves degradation under specified conditions. Neither claim can be established from the look of a pouch; assess the complete structure and the facilities available in the destination market.

Thickness is not the whole story

A thicker film can improve mechanical resistance, but barrier performance depends on the materials and construction, not just total microns. Evaluate the layers and the finished pack together.

The inner layer contacts the product

Check the contact layer and the intended conditions of use in the supporting documents. The outer appearance does not establish suitability for the product inside.

Closures

Closure options for custom pouches

Each option adds manufacturing and performance requirements. Consider its benefit, the available filling space and how the customer will use the pack.

Closure options: benefits and trade-offs

Option	What it adds	Trade-off	When to consider it
Slider zip	Convenient reclosing	Additional cost and reduced fill height; check powder buildup	Products used over several weeks
Press-to-close zip	A compact reclosable profile	Opening and reclosing force must be checked	Dry products and repeat use
Resealable adhesive strip	Reclosing without a thick zip profile	A limited number of reopening cycles	Snacks and smaller fills
Tear notch	A controlled opening without scissors	Position must be checked on the artwork template	A useful starting point for controlled opening
Degassing valve	Release of gas from freshly roasted coffee	Additional cost; intended for products that release gas	Freshly roasted coffee, depending on packing time
Clear window	A view of the product	Reduced light protection in the window area	Products whose appearance matters and which tolerate light exposure
Euro slot	Hanging display	Must be positioned above the sealed product area	Packs intended for hanging display
Premium finishes	Soft-touch, hot foil, spot varnish and holographic finishes	Each finish requires its own manufacturing and inspection checks	Premium presentation

Consider a tear notch for controlled opening, and use a Euro slot only when the display requires it. Test the zip with the actual product, especially fine powders. For sealing after filling, review the equipment guide: continuous pouch sealing equipment.

Quality commitments

Put the production requirements in writing

The quote should define more than a unit price. Agree the physical reference, inspection evidence, file handling and tooling terms before approving the order.

Four points to agree in writing

What happens if production differs from the approved sample
Agree what the sample represents and how deviations in material, construction or finish will be handled. Any replacement or credit terms should be set out in the quote, with the acceptance criteria.
Inspection photos and videos before shipment
SKLUBS coordinates production checks through its Guangdong team. Agree the inspection scope and the evidence to be supplied before shipment: seals, colour reference, closure performance and packing.
Confidentiality for your artwork
Your files and designs belong to your project. Agree how they may be shared within the production chain, and put the confidentiality terms in writing before sending sensitive artwork.
Ownership and reuse of the cutting tool
Custom dimensions may require a cutting tool. Ask how it is charged, who owns it, how long it is retained and whether it can be reused for repeat orders. These terms belong in the quote.

These points should appear in the quote. Ask for any missing terms before approving production.

Documents to request for your order

Declaration of complianceFor the relevant use and destination; references may include Regulation (EC) No 1935/2004, where applicable to the intended use and market
Film specificationLayer-by-layer composition and thicknesses in microns
Factory and material documentationRequest the relevant factory and material certificates for the proposed supplier and specification; check scope and validity
TraceabilityFilm-roll reference and conversion date linked to the batch

Pricing

Digital printing or factory-direct production: compare your project

Different production models suit different volumes and specifications. Compare setup, materials, finishes and delivery on the same basis before choosing a supplier.

Two production models, compared by project requirements

Criterion	Digital printing in Europe	Factory-direct production
Minimum order quantity	Small batches, depending on the supplier	From 250 units per design and format, subject to specification
Lead time	Confirm production and delivery with the supplier	Standard production reference: 5–7 days, plus transport; confirm in the quote
Formats	A catalogue of standard dimensions	Custom dimensions, with tooling specified separately
Film structures	Available film catalogue	Specified layer by layer for the product and intended shelf life
Finishes	Gloss, matt and selected soft-touch options	Soft-touch, hot foil, spot varnish and holographic finishes
Unit price at 250 pieces	Compare the complete delivered quote	Setup and transport represent a larger share of a small batch
Unit price at 1,000 pieces	Depends on the specification	Compare like-for-like film, finish and delivery terms
Unit price at 5,000 pieces or more	Request a quote for the actual volume	Setup costs are spread across a larger batch

For a small launch, compare digital printing with a factory-direct quote. Minimums, setup costs and transport can change which model suits the project. Assess complete delivered offers rather than unit prices alone.

What influences the price most?

Quantity per design is a major factor. Two designs require separate planning and may incur different setup costs from one larger run. State the quantity for each design before comparing materials and finishes.

Costs beyond the unit price

Ask what the price includes: production, tooling, packing and freight. Confirm the named delivery destination and the buyer’s import responsibilities. An ex-factory offer and a delivered offer are not directly comparable.

The cutting tool

For a custom format, tooling may be charged separately. Ask about ownership and repeat-order use, and compare the setup charge against your expected volumes.

The sample

Confirm whether the sample is free, charged separately or credited against the order, and what specification it represents. Agree these terms before paying for it.

Common mistakes

Common mistakes when developing a pouch

The following checks help prevent mismatches between the brief, artwork, sample and production batch.

What can go wrong

The colour changes between orders. A repeat run no longer matches the packs already on the shelf.