Flexible packaging continues to dominate the market and is estimated to reach a market size of $373 billion by 2030. As businesses move to this packaging type, they often face a difficult question: Should they choose printed rollstock or pre-made pouches? In this blog, we’re breaking down the differences, benefits, and best uses for each. By the end, you’ll be able to make a confident, well-informed decision for your organization.

What is Printed Rollstock?

Printed rollstock is continuous printed film that’s wound on a roll and used with form-fill-seal (FFS) machinery. It’s fed into automated packaging equipment that creates the final desired product.

This type of packaging is often used for high-volume products like snacks, coffee, pet food, and single-serve items. It offers a lower packaging cost per unit and is ideal for automation and efficiency. Many businesses rely on printed rollstock because it’s faster for large run production.

What are Pre-Made Pouches?

Pre-made solutions are ready-to-fill pouches that are pre-converted and supplied in finished form. This might include stand-up, flat, and spouted pouch options, among others. These are ideal for premium, small-batch, and limited-edition products. They’re also an ideal choice for startups entering the retail space, as they may not have FFS equipment.

Should You Choose Printed Rollstock or Pre-Made Pouches?

If you’re wondering whether pre-made pouches or printed rollstock is best for your business, there are a few items to keep in mind:

Production Volume and Scale

The first thing to consider is production volume and scale. Are you running thousands of units or hundreds? If you’re running large volumes, you may want to invest in FFS equipment and pair it with a rollstock solution.

Budget and Equipment Access

Next, take a look at your budget and equipment access. Do you have FFS machinery or will you rely on co-packers? As mentioned above, FFS equipment will allow you to use rollstock in your operations.

Lead Times and Flexibility

Do you need a quick turnaround or frequent design changes? If so, it may be best to opt for pre-made pouches that you can customize during reorders.

Tips for Making the Right Decision

Rollstock is usually better for large-scale food or beverage brands prioritizing speed and cost-efficiency. Additionally, manufacturers looking to integrate into automated lines will see great results with rollstock solutions. And lastly, businesses with stable SKUs and high-volume demand often invest in rollstock.

On the other hand, pre-made pouches will be better for startups, niche brands, or seasonal product lines. These businesses usually don’t have the FFS equipment needed for rollstock, which makes pre-made pouches the best solution.

Work with PPC Flex for Your Packaging Needs

Need printed rollstock or pre-made pouches that fit your exact requirements? Turn to PPC Flex. As an advanced flexible packaging manufacturer, we’ve been providing powerful, purposeful packaging solutions for decades. Through our experience, we’ve seen the profound impact packaging can have on the growth of a business. That’s why we develop a deep understanding of your needs to deliver the best packaging, every time. We’ll help you grow by finding the right flexible packaging solutions that preserve products and deliver a better consumer experience.

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