Shaped Pouches: The Ultimate Guide

What are Shaped Pouches?

Shaped pouches are flexible packaging bags that are permanently formed into unique non-rectangular shapes during the manufacturing process.

They break away from the standard pillow, gusseted or stand up pouch silhouette to take on distinctive 3D shapes like animals, fruits, bottles or other objects.

Shaped pouches allow brands to create innovative packaging that mirrors product shape, ties into branding themes, or improves ergonomics and handling.

Benefits of Shaped Pouches

Shaped pouches provide several advantages:

Unique and Distinctive

The customized shapes stand out on shelves and differentiate brands. They can reflect product personality.

Increased Shelf Appeal

Unique shapes attract consumer attention and interest far better than standard pouches.

Improved Ergonomics

Shaping pouches to fit hand contours or match product use can improve handling and utility.

Flexible and Lightweight

Shaped pouches retain the filled weight and storage benefits of conventional flexible pouches.

Shaping Technologies for Pouches

Two common methods used are:

Horizontal Form Fill Seal

Pouches are formed, filled and sealed horizontally utilizing specially designed dies that shape the bag film.

Vertical Form Fill Seal

Film unwinds vertically through forming dies that create the unique shape before filling and sealing occur.

Materials Used for Shaped Pouches

Laminated Films

Polymer and foil laminations that can hold 3D shapes when sealed. Provide durability.

Plastics

PET, PP and polyethylene films offer the pliability needed for forming and shaping.

Foils

Aluminum foils maintain barrier properties and shape when laminated with polymers.

Branding Shaped Pouches

Embossing and Debossing

Imprinting shapes, logos adds prestige. Debossing creates recessed areas for branding contrast.

Printed Graphics

Full color printing brings pouches and shaping themes to life.

Labels and Sleeves

Shaped pouches allow innovative labels, sleeves, opening tabs and closures to be added.

Applications of Shaped Pouches

Food and Beverage

Fruit, candy, chocolate, nuts, snacks, sauces.

Personal Care

Shampoo, soap, cosmetics.

Household Goods

Kitchen tools, cleaning products, automotive fluids.

The Future of Shaped Pouches

  • Increase adoption as brands realize differentiation advantages
  • High-barrier materials to allow more food products
  • Digital printing increasing short run possibilities
  • Shaping used for sustainability messaging

Conclusion

Shaped pouches enable unique structural packaging that provides shelf appeal, ergonomic and branding benefits compared to standard pouches. Continued innovations will expand their versatility across many CPG categories.

FAQs

What products are commonly packaged in shaped pouches?

Shaped pouches work very well for food items like chocolates, confectionery, nuts, dried fruits, and baked snacks.

Are shaped pouches recyclable?

If made using a mono-material like all polyethylene, shaped pouches can be recycled. Heavily laminated pouches are more challenging to recycle.

Do shaped pouches have a higher cost?

Yes, shaped pouch production involves specialized equipment and greater material usage resulting in higher costs compared to standard pouches.

Are shaped pouches suitable for liquids?

Shaped liquid pouches require very robust sealing to prevent leakage. They work better for viscous fluids or gels.

Can shaped pouches be microwaved?

Yes, if made from microwave-safe materials like polypropylene or polyethylene. Any susceptors are shielded from direct heating.

How is product loaded into shaped pouches?

Most shaped pouches are vertically form filled so products like nuts, candies are gravity fed from overhead hoppers into the formed pouch.

 

Shaped Pouches