6 Things to Consider When Choosing a Flexible Packaging Converter

HOW TO SELECT A FLEXIBLE PACKAGING CONVERTER AS A BRAND

In the modern world, it is no longer enough to simply create a quality product that consumers love. The way a product is packaged is becoming more and more important to consumers, brands, and regulating bodies alike. Increasing scrutiny is applied to everything from the materials used in packaging to the marketing claims made on it. On the other hand, brands must ensure they remain competitive by balancing low material costs, high margins, and skillful targeting of their market segment.

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For all of these reasons, it is absolutely crucial for brands that utilize flexible packaging to partner with a trustworthy converter whose operations and goals align with their own. Certain factors, such as lead times and acceptable customer service, may immediately come to mind. However, there are many other things brands should take into account when deciding whether or not to move forward with a packaging producer.

1. What are their equipment capabilities?

In many ways, a flexible packaging operation is defined by the equipment in its facility. There are three main types of equipment brands should ask about when deciding if they should do business with a flex pack converter:

Presses

Does the converter use a conventional press or a digital press? Each type of press has its own benefits and drawbacks that will impact each brand differently.

Conventional presses, which include flexographic and rotogravure presses, can process huge volumes in a very short time; however, they typically incur longer lead times due to the complexity of pre-press logistics and planning. Converters who have a conventional press will likely be able to offer more flexibility regarding types of packaging and the construction of that packaging.

Digital presses are incredibly accurate and can turn a graphic file into a pallet of finished prints in a very short time frame, but they produce packaging with certain limitations that affect versatility and performance. They are typically best suited for shorter runs with higher margins.

Any option could be ideal depending on the brand, but in general, a rotogravure press is the most suitable option for the highest quality jobs, followed by the flexographic press and then digital technology. Be sure to find a converter whose capabilities align with your own, and don’t be afraid to ask questions about their printing process to gain a fuller understanding of their capabilities.

Embellishments

The equipment that makes certain value-add processes possible can be expensive, so not every converter will offer every value-add effect. Be sure to ask about the converter’s familiarity with foiling, spot varnishes, viewing windows, tear notches, and any other extra processes your packaging may need during any initial business discussions.

Fitments

Similar to embellishments, fitments typically require dedicated machines or modules and can be a pricey investment for a converter. Ask your potential partner if they have the ability to add elements such as zippers, valves, spouts, and other consumer-friendly components to packaging if your brand has a need for them.

2. What is their minimum order quantity?

Perhaps the most basic question on this list, a flexible packaging converter’s minimum order quantity is a straightforward way for a brand to determine compatibility. In fact, many converters will not even consider partnering with a brand with order volumes that fall outside their pre-determined range.

Larger converters will likely have high minimum order quantities to maximize the productivity of their presses and employees. These larger converters will likely turn away smaller brands simply because it does not make financial sense to let smaller jobs take up valuable space on the press when a larger, more profitable job might be edged out of the workflow.

On the other hand, some flex pack converters, such as those with digital presses, may specialize in smaller orders and refuse jobs that exceed their order limits. These restrictions may be due to equipment constraints or concerns about the lower margins that typically accompany high-volume jobs. Pushing the limitations of a converter’s output can result in extended lead times or poor quality control, leading to frustration for both the converter and the brand.

To ensure the brand/converter relationship remains positive, stress free, and productive in the long term, be sure to find a converter whose volume capabilities fit comfortably within your business’s needs. Brands experiencing high rates of growth may also need to verify that their converter’s upper range falls within their expected growth targets for the foreseeable future.

3. What packaging formats do they offer?

Flexible packaging comes in a wide variety of shapes, sizes, and formats, and a given converter rarely offers every existing iteration. Certain converters may even specialize in a specific format, such as stand-up pouches or stick packs, based on their equipment capabilities and target market.

One of the first questions to ask in an initial call or meeting is if the flex pack converter can provide the full range of packaging formats your business will need at an acceptable quality. A brand that markets its products as high end will need to confirm that the converter can not only produce the package but also produce it with consistently excellent results.

It is also important to consider a converter’s full product offerings even if your company does not have a current need for many of them. This information may affect your product development team’s willingness to trial new products and materials as having a reliable packaging vendor can greatly streamline the process. Even if a converter does not currently offer a packaging format your team is interested in trying out, many will be willing to explore new formats when asked.

If your brand lies on the more creative end of the packaging spectrum, be sure to find out if your converter has dedicated systems in place for integrating new packaging. Confirm that they have in-house research and development staff that can devote time to working with your team on creating packaging that meets your brand’s exact needs.

4. Are the structures they offer suitable for your target market?

While the form packaging takes is certainly important for consumer experience and marketing efforts, the internal structure of a package is far more important when it comes to consumer safety and abiding by legislative and regulatory requirements. Brands would be wise to thoroughly research federal and local laws that might impact the way they package their goods and, in turn, seek out flexible packaging converters who also understand these criteria.

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Food safety and material handling certifications are of utmost importance for many types of products, so always be sure you fully understand where the converter’s materials are coming from and how each facility in their supply chain operates (including if the facilities have a food-safety certification). If you sell controlled substances, make sure the converter offers packaging that meets the proper requirements, such as child-proof packaging.

Consider also if the converter offers packaging with aesthetic qualities that will support your marketing efforts. Historically, flex pack converters have given little attention to specialty design elements, but it is becoming increasingly more common to find converters who utilize specialty finishes and value-add effects for marketing purposes.

If your brand has little need for specialty packaging, you may be able to find a converter that uses basic materials with the expectation of smaller margins. However, if you are a luxury brand or operate in a more niche market, it can be helpful to find converters who offer more creative solutions, such as a velvety soft-touch finish or eye-catching embellishments.

If you’d like to learn more about how flexible packaging is made, check out our blog post on the topic: How Is Flexible Packaging Made?

5. Do they offer enough flexibility to serve you long term?

The need for flexibility is closely intertwined with the concerns laid out in the previous two sections, but it is important to understand what factors might affect a converter’s ability to switch gears when needed. Most flexible packaging is made up of several individual layers that each serve a specific purpose.

Because this process requires converters to source materials from a variety of vendors, many smaller or newer converters will instead purchase pre-laminations, also called pre-lams, which are structures that have already been assembled in another facility. In these instances, the flexible packaging converter will have little control over the price, thickness, and construction of their packaging.

If your company wants to be highly involved in the engineering and design process to create personalized packaging solutions that meet specific criteria, seeking out a converter that creates structures in-house will prove to be highly beneficial. These converters will have in-house application engineers who understand how a structure can be altered to meet the goals of your brand without sacrificing safety or quality.

6. Do your sustainability goals align?

Sustainability is becoming more important to consumers and governing bodies alike, so having a solid grasp on a flexible packaging converter’s sustainability initiatives is crucial. If this is something central to your company’s goals or mission statement, request information about what steps the converter is taking regarding consumer social responsibility (CSR).

Consider the following questions:

• Do they offer sustainable materials that help reduce post-consumer waste or the amount of emissions produced in the manufacturing process?
• Have they taken any steps in their internal processes or systems to reduce their energy usage or find more mindful solutions?
• Do they carefully engineer their packaging structures to help minimize food waste?
• Have they made efforts to stay informed about the latest developments in sustainable packaging?
• Are they willing to share their insights and provide education about available solutions?

Brands that promise consumers some level of sustainability must accept accountability not only for the products they sell but also for the packaging that holds them. This means understanding the inner workings of vendors and the entire supply chain in order to be fully honest in any sustainability claims.

WANT GUIDANCE ABOUT HOW TO APPEAL TO BRANDS?

If you are a flexible packaging converter hoping to use this article as an educational resource, don’t hesitate to reach out to the Nobelus team through or . Our in-house solutions experts have years of experience and insights about learning how to work with brands to find solutions that meet the needs of both parties. We can provide you with detailed guidance on food safety regulations, entering new markets, offering a wider range of packaging formats, and even deciding which type of press you should invest in based on your operation’s goals.

Flexible Packaging FAQs

If you’re among the many companies making the move from rigid to flexible packaging, it’s likely you have questions as you select the best packaging type and supplier. Based on Fres-co’s extensive experience with customers across the food, beverage, chemical, and agricultural chemical markets, we’ve developed this FAQ-based flexible packaging guide to help educate you as you make the switch.

What benefits does flexible packaging offer vs rigid alternatives?

One benefit of flexible packaging that has significant ripple effects is its lighter weight. A lighter package comes with lower transportation and storage costs (making it ideal for e-commerce) and reduces the total carbon footprint associated with your packaging, particularly compared to glass or plastic bottles, metal cans and rigid drums. Flexible packages also have a lower product-to-packaging ratio, which reduces waste and further improves sustainability.

When it comes to ensuring product quality and integrity, flexible packaging is a smart choice. For example, flexible industrial bags offer a far lower oxygen transmission rate (OTR) and lower moisture vapor transmission rate (MVTR) than rigid drums, providing greater product protection and extending shelf life. And since flexible packaging isn’t susceptible to breakage and damage like glass or metal, it further improves product protection while minimizing waste.

Safety is another factor where flexible packaging outshines rigid alternatives. Many companies find palletization is safer and more stable when they use flexible bags or pouches, while those in foodservice find it’s safer for employees to open and use a flexible pouch or bag-in-box vs metal cans.

And finally, flexible packaging can improve shelf appeal by enabling you to offer products in unique package shapes and sizes with highly impactful graphics on a larger brand billboard.

What should I consider when choosing a flexible packaging solution?

When providers like Fres-co consult with a company that is new to flexible packaging, we advise them that the following factors influence the optimal packaging choice:

• • The type of product
  • How the product is currently packaged
  • Your objectives in switching to flexible packaging
  • How the product will be transported or distributed through the supply chain (via domestic or international routes, by truck or container, over short or long distances)
  • Whether the product is highly sensitive to moisture or oxygen
  • The packaging types and sizes you’ll need for different environments and distribution channels (e.g., food and beverage companies might sell through retail stores, club/warehouse stores, and e-commerce)
  • The desired shelf life you want to maintain from end to end
  • Safety-related requirements and considerations (such as the risk of injury when lifting or palletizing packages, the presence of combustible dust, and the need to comply with Department of Transportation, United Nations, or other agency regulations)
  • Customer- or industry-specific requirements, including sustainability expectations
  • Whether you plan to fill your packaging in-house (which impacts the choice of packaging type and filling equipment) or you’ll use a co-packer or contract packager instead

What are the most common types of flexible packaging? 

There is a flexible packaging type for almost any application in the food, beverage, chemical, and agricultural chemical markets. Following are the most common flexible packaging options:

• • Stand-up pouch with a zipper or spout closure, which is ideal for beverages and dry foods  

• • Flat pouch (also called a pillow pouch), which is easy to palletize and appropriate for dry or liquid products, including some chemicals and agricultural chemicals

• • Corner seal pouch, which is often used in foodservice applications 
  • Gusseted bag, which is often used in retail applications, including whole and ground coffee beans

• • Block bottom bag or pouch, which combines a premium look with superior shelf stability and is ideal for products like coffee, nuts, other snack foods, and pet foods   

• • Rollstock that can be custom printed and used on automated equipment to form and fill packaging

• • Bag-in-box, which provides easy handling, shipping, and storage for shelf-stable or refrigerated liquid products 

• • Flexible intermediate bulk container (FIBC), also known as a bulk bag, which is suitable for coffee, chemicals, and agricultural chemicals

• • Industrial bag, which protects chemicals, agricultural chemicals, resins, and food-and-feed ingredients against moisture, oxygen, and insects

How can flexible packaging support my sustainability mission? 

Flexible packaging is especially well-suited to supporting a company’s sustainability mission in several ways. With a lower product-to-package ratio than rigid options, flexible packaging reduces waste and equates to a lower carbon footprint, in part by reducing the greenhouse gas emissions generated during transportation. Some types of flexible packaging—including the bag-in-box and various types of pouches—consume fewer resources during production as compared to glass bottles, metal cans and plastic containers. Additionally, recycle-ready flexible packaging is available to further meet the goal of recyclability as a sustainable solution.  

If I move to flexible packaging, what printing options will I have?

Flexible packaging supports a variety of printing options, giving you the flexibility to choose the best method for your needs. 

Traditional methods like rotogravure or flexographic printing are ideal when you’re printing flexible packaging in large quantities, since they require setup fees for plates and cylinders, as well as minimum quantities. Digital printing is a better choice when you’re printing flexible packaging in smaller quantities and/or you need faster turnaround than is possible with traditional methods. Companies that produce their products in small batches, and those that offer seasonal, limited time, or exclusive products, find digital printing to be an attractive choice. 

What type of customization does flexible packaging support?

When you switch from rigid to flexible packaging, you’ll enjoy access to a wide range of customization features. Though they vary by specific packaging type, most flexible packaging options support customization of:

• • Size
  • Shape
  • Graphics and colors
  • Material (including recyclable, compostable, and biodegradable choices, as well as package transparency features)
  • Closure or seal (including zippers, spouts, and other reclosure features) 
  • Barrier (including the number and type of barrier layers)
  • Dispensing features (including fitments designed into the packaging material, as well as separate spouts and taps)

What should I look for in a flexible packaging provider?

When you transition from rigid to flexible packaging, you’ll want the support of an experienced partner capable of delivering a smooth experience from start to finish—as well as ongoing service that enables you to realize all the advantages that flexible packaging has to offer. When choosing a flexible packaging provider, be sure to look for:   

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• • A history of industry-leading innovations (like Fres-co’s patented one-way degassing valve) that improve packaging performance
  • In-house R&D capabilities you can leverage to arrive at the best possible packaging solution for your needs
  • The ability to develop custom package designs and sizes, with custom samples provided upfront to ensure the optimal solution
  • Technical service, operational support, and spare parts provided domestically, for the best response times
  • Training for your logistics and operations staff, with support provided during your test runs right through to your first production run 
  • High-quality printing services provided in-house
  • Expert guidance on making the transition from rigid to flexible packaging as smooth, seamless, and successful as possible