Curious to know how flexible packaging manufacturing works? If you’re looking for a packaging provider, knowing these details can help you get a quality partnership. Below, our team defines what flexible packaging is and how the manufacturing process works. That way, you can feel confident in making a decision for your business.
What Flexible Packaging is Made of
Flexible packaging is made of polymer-based raw materials that are melted, formed, and combined to create the films that protect your product. The two most common base materials are HDPE and LDPE. High-density polyethylene (HDPE) is a stiffer, stronger material with good moisture barrier properties. Low-density polyethylene (LDPE) is more flexible but still offers high-quality protection.
At PPC Flex, we also offer a range of sustainable flexible packaging options. These solutions help our customers appeal to eco-conscious consumers and comply with industry regulations. Our Thrive line offers recycled solutions, along with compostable options. Learn more about these offerings here.
Film Extrusion
The first step to creating flexible packaging is film extrusion. The material is fed into a heated barrel where it’s melted and pushed through a die. After this, the film either enters a blown film, cast film, or co-extrusion process. Each offers the same result: a raw, unprinted roll of material that serves as the foundation for your packaging.
Lamination
A single layer of film usually is not sufficient to protect products. That’s where lamination comes in. It combines two or more layers of film together to create a multi-layer structure. The final laminated structure might include three, four or more layers, depending on the application.
Here’s an example: a flexible snack pouch might combine a printed outer layer for appearance and stiffness, a middle foil for barrier performance, and an inner layer for heat sealing. This ensures that the pouch performs well under real-world conditions.
Printing
Printing is an easy way for brands to stand out on retail shelves. It allows brands to add eye-catching graphics, brand information, and important product details. Many flexible packaging manufacturers will use either flexographic or digital printing.
Flexographic printing uses a plate to transfer ink onto the material as it passes through the press. With modern technology, this process can produce high-quality results across medium- to high-production runs.
Digital printing does not use plates to transfer ink onto the substrate, which is ideal for switching between designs. It’s a viable option for shorter runs and offers flexibility in go-to-market strategies.
Partner with PPC Flex for Your Packaging Needs
Looking for a flexible packaging manufacturing partner you can trust? Turn to PPC Flex. We’re a global brand, working with some of the largest companies in the world. At the same time, our team provides the individualized service you’d expect from a small shop. We help with everything from the initial design to the final shipment. Contact us today to get started.