Flexible Packaging
Pouches, Sachets, Refill Packs & Stick Packs
Flexible Packaging Formats We Offer
Stand-Up Pouches
One of the most versatile and popular formats, stand-up pouches (SUPs) provide excellent shelf presence and are ideal for dry powders, supplements, snacks, and personal care refills.
Key Features:
- Resealable zippers, tear notches, and spouts available
- Multi-layer laminates for barrier protection against oxygen, moisture, and light
- Available in compostable, recyclable mono-material, and PCR (post-consumer recycled) structures
Flat Pouches & Sachets
Perfect for sample sizes, single-use doses, or travel packaging, flat pouches and sachets are commonly used for powders, creams, capsules, and liquids.
Benefits include:
- Heat seal and fin seal options
- Available with easy-tear openings and portion-control designs
- Ideal for clinical trials, promotions, and on-the-go formats
- Compatible with digital or high-speed printing for detailed branding
Refill Packs
Flexible refill packaging is gaining traction across industries for its reduced material use, lower carbon footprint, and convenience. Refill packs are designed to replenish rigid containers and support both sustainability and customer retention.
Why Brands Love Them:
- Lightweight and compact, reducing shipping costs and emissions
- Custom-fit for a variety of dispensers, bottles, and jars
- Available with spouts, fitments, or tear-top designs
- Supports concentrated product formulations that reduce water and packaging waste
Printing & Decoration Options
- Rotogravure & Flexographic Printing: Delivers high-quality, full-color graphics with cost-efficiency for larger runs.
- Digital Printing: Ideal for short runs or frequent design changes, offering vibrant imagery and rapid turnaround.
- Matte, Gloss, or Soft-Touch Finishes: Enhance shelf appeal with tactile and visual differentiation.
- Spot UV, Metallic Inks, and Foils: Add premium detailing for elevated branding.
Sustainability in Flexible Packaging
Lightweight & Efficient
Flexible packaging requires significantly less material than rigid formats, leading to reduced manufacturing inputs and lower carbon emissions during transport. This lean footprint makes it a strategic choice for brands aiming to meet carbon reduction goals.
Compostable & Biodegradable Options
Pouches and sachets are made from bio-based materials that meet industrial compostability standards. These options are designed to break down in controlled composting environments, supporting zero-waste initiatives.
Recyclable & PCR Films
Mono-material flexible packaging structures are designed for recyclability and offer options made with PCR content. These formats help brands reduce virgin plastic usage and support compliance with regulations like SB54.
Extended Shelf Life
Flexible packaging structures can be engineered with high-barrier layers to prevent moisture, light, and oxygen infiltration, extending product freshness and reducing spoilage or returns.
Custom Engineered for Your Product
NuGen collaborates with clients to engineer the ideal flexible packaging format for their unique product needs. Whether your priority is barrier protection, sustainability, or user-friendly dispensing, we guide you in selecting the right materials, structure, and design elements to deliver optimal performance.
From single-serve stick packs to eco-friendly refill pouches, NuGen’s Flexible Packaging options deliver on sustainability, protection, and customer convenience—helping your brand meet today’s packaging challenges with confidence.
Frequently Asked Questions
1. What types of flexible packaging formats does NuGen offer?
We offer a wide range of flexible packaging formats, including stand-up pouches, flat pouches, sachets, refill packs, and single-serve stick packs. Each option can be customized for specific product applications in the nutraceuticals, pharmaceuticals, personal care, food, and wellness industries.
2. What are the key benefits of flexible packaging compared to rigid packaging?
Flexible packaging is lightweight, space-saving, and uses significantly less material than rigid formats, resulting in lower shipping costs, a reduced carbon footprint, and easier storage. It also offers high barrier protection and extensive customization for branding and performance.
3. Is flexible packaging sustainable?
Yes. Our flexible packaging solutions include recyclable mono-material structures, PCR (post-consumer recycled) content, and industrially compostable materials. These options help brands reduce virgin plastic use, meet sustainability goals, and align with legislation such as California’s SB54.
4. Can I use flexible packaging for refill applications?
Absolutely. Our refill packs are designed to reduce material waste and support concentrated formulations. These lightweight pouches can be fitted with spouts, fitments, or easy-tear tops, making them ideal for refilling bottles, jars, and dispensers.
5. What kinds of products work best with stand-up pouches?
Stand-up pouches (SUPs) are ideal for powders, snacks, capsules, and personal care refills. They offer strong shelf presence and are available with zippers, spouts, and multi-layer barriers for maximum protection.
6. Are there flexible packaging solutions for single-use or travel-size products?
Yes. Flat pouches and sachets are perfect for samples, single-dose products, and travel-size formats. They’re commonly used for creams, powders, capsules, and liquids, and can include easy-tear designs for consumer convenience.
7. What decoration and printing options are available?
Depending on your run size and design needs, we offer high-quality rotogravure, flexographic, and digital printing. Finishing options include matte, gloss, soft-touch, metallic inks, spot UV, and foil accents to elevate your branding.
8. How does flexible packaging help extend shelf life?
Our flexible materials can be engineered with high-barrier laminates that block oxygen, moisture, and light, preserving product freshness, reducing spoilage, and extending shelf life.
9. Can NuGen help us choose the right flexible packaging structure for our product?
Yes. We work closely with each client to custom-engineer the right packaging solution based on your product’s formulation, shelf life needs, sustainability targets, and brand goals.
10. Is flexible packaging compliant with recycling and packaging regulations?
Our recyclable and PCR-based flexible films are designed with compliance in mind, including support for evolving EPR and PCR regulations like California SB54. We’ll guide you through the options that align with your compliance strategy.