Flexible pouches have become one of the fastest-growing packaging solutions across industries, offering numerous advantages over traditional rigid packaging. At ZACROS, we specialize in flexible pouches for non-food liquid applications, delivering high-quality solutions that meet both performance requirements and sustainability goals. Our commitment to innovation drives us to develop flexible pouches that enhance the consumer experience while minimizing environmental impact.
Recycle-Ready MONOSOLUTIONS®
Our innovative recycle-ready monomaterial liquid flexible pouches deliver the same performance as traditional laminated options at competitive prices. Although recycling systems are still evolving, adopting these pouches now prepares your brand for future sustainability mandates and growing eco-conscious consumer demands. MONOSOLUTIONS™ are available in all the formats below.
Case Study:
Japan’s Refill Revolution – Transforming an Industry
In the 1990s, Japan pioneered refill pouches to tackle its plastic waste problem. By 2021, the country achieved a remarkable 43% reduction in plastic packaging for home and personal care products compared to 1995 levels through refill and reuse packaging.
As a leading pouch manufacturer, ZACROS has helped transform the retail landscape. Today, refill pouches occupy over 70% of retail shelf space, demonstrating the powerful impact of sustainable packaging innovation. This Japanese success story illustrates that simple packaging adjustments can lead to substantial benefits to our environment.
Sustainability Benefits of Flexible Pouches
FAQs
What are the benefits of flexible pouches?
There are reasons why brands choose flexible pouches over alternative packaging. Flexible pouches offer benefits for not just brands but also consumers.
Sustainability
Life Cycle Assessment (LCA) proves that flexible pouches reduce overall environmental impacts from greenhouse gas emissions to resource usage. You can download the Sustainability Benefits of Flexible Pouches.Performance
Film structures can be modified easily to meet performance requirements such as oxygen and light barriers. Also, flexible pouches are durable and less likely to be affected by cosmetic abrasion.Usability
Flexible pouches are less bulky, making them convenient to store and carry. A high evacuation rate helps consumers efficiently use all the product contents.Customizability
Shape, size, film structure, and design can be customizable. Customizability helps brand owners to differentiate, and products can stand out on shelves or websites.
Are flexible pouches recyclable?
The short answer is Yes and No. Increasing monomaterial pouches are coming out even for liquid applications, including our MONOSOLUTIONS® Flowpack series. However, the current US infrastructure doesn’t support a collection of many recyclable-ready packaging.
Many products use multi-materials unrecyclable flexible pouches, yet they can significantly reduce the packaging that goes to landfill significantly. In addition, there are options to recycle through programs like TerraCycle.
Are pouches better than plastic bottles?
Depending on your priority, pouches can be better than plastic bottles. Both packaging has pros and cons. Combining a pouch and a bottle may be suitable in some applications, such as refillable home & personal care and cosmetic products. Download a guide to Choose the Right Liquid Packaging to learn more about the benefits and drawbacks of different types of liquid packaging.
What are flexible pouches made of?
Polyethylene (PE) and Polypropylene (PP) are flexible pouches' most common base materials. In the US, PE is by far the most used plastic film material for liquid applications. PE can be divided into three different categories: high-density polyethylene (HDPE), low-density polyethylene (LLPE), and linear low-density polyethylene (LLDPE). Depending on the required barrier properties, different types of PE or PP are laminated with Nylon, metal foil, and polyethylene terephthalate (PET).
What are the types of pouch bags for liquids?
There is various type of pouches available depending on your needs and applications. A pillow and stand-up pouch are the most common bag types for liquid products.
Pillow pouch
A pillow pouch is also known as a flat pouch. Form-fill-seal equipment (one equipment can form a package, fill it with a product, and seal the package) is often used to manufacture pillow pouches. Examples are cosmetics sample sachets and travel-size personal care pouches.
Stand-up pouch
A stand-up pouch has a bottom gusset that allows it to stand up. The most common closure for liquid applications is a spout. ZACROS Flowpack NT & PL series are spoutless while keeping the functionality of a spout.
How are stand-up spouted pouches filled?
Pre-made spouted pouches can be filled through a spout or from a top. Pouches are typically loaded to a rail system when you fill through a spout. When you fill from the top, a spout and a cap are intact, and there is no need to torque down the cap. After filling, heat seal the top.
ZACROS is an expert in liquid flexible pouches for cosmetics and personal & home care products with over 25 years of experience. You should not sacrifice performance to improve packaging sustainability. We are here to support you, from material selections to finding a filler. Contact us today to get started with your project.