Learn how flexible packaging is manufactured—from material selection and high-resolution printing to advanced finishing techniques.
We deliver premium, brand-enhancing packaging solutions that improve shelf appeal and product protection, which we’ll expand on today.
Table of contents
What is flexible packaging?
Flexible packaging refers to packaging made from easily shaped materials, such as paperboard, film, or foil, that adapts to the shape of the product. It’s cost-effective, lightweight, and designed for high visual impact.
Spectrum specializes in flexible packaging, ideal for pharmaceuticals, cosmetics, and more!
Types of flexible packaging
Flexible packaging comes in many versatile forms, each crafted to match unique product needs, production methods, and shelf requirements:
Flexible pouches
Pouches are among the most popular forms of flexible packaging—offered in stand-up, flat, or gusseted styles:
Perfect for snacks, beverages, supplements, and pet food, these pouches are lightweight, easy to store, and very consumer-friendly. Many feature resealable zippers or spouts, which help preserve freshness, prevent spills, and promote reuse.
Their print-friendly surfaces also allow for high-impact branding and nutritional information placements.
Flexible bags
Flexible bags provide robust, customizable solutions–a perfect fit for a variety of industries!
Gusseted bags expand to hold bulkier products, while vacuum-sealed options remove oxygen to lock in freshness—ideal for perishable goods like coffee, grains, meats, and frozen meals.
These bags can be designed with tear notches, handles, or clear windows to improve functionality and consumer trust.
Sachets
Sachets are small, single-serve packets commonly used for condiments, beauty samples, health supplements, and pharmaceutical products.
Their compact form makes them ideal for on-the-go use and product sampling!
They’re also a cost-effective solution for trial-size offerings, and the controlled dosage they provide is beneficial in regulated industries like healthcare.
Rollstock
Rollstock is a continuous roll of pre-printed or plain film used in form-fill-seal machines.
Sometimes called ‘rollstock film’, it’s ideal for companies with high-volume packaging lines, enabling quick turnaround and consistent presentation.
Rollstock is commonly used in snack foods, protein bars, and medical supplies, where speed and reliability are key. This format supports various substrates and barrier properties, including moisture, light, and even oxygen resistance.
How is flexible packaging made?
Creating high-performance flexible packaging requires precision, quality materials, and cutting-edge technology. Here’s how we do it:
Step 1: Material Selection
The process begins by selecting the optimal materials for your product. This may include paperboard, laminated films, aluminum foil, or biodegradable substrates.
Each material is chosen based on its barrier properties, durability, and print compatibility to ensure it matches both product protection and brand positioning.
Step 2: Printing
Next, we apply your branding using advanced flexographic or digital printing techniques. Our high-resolution printing ensures every color, logo, and design element is crisp, accurate, and aligned with your visual identity.
This step is critical for shelf appeal and regulatory compliance.
Step 3: Coating & Finishing
We enhance the surface with coatings that serve both functional and aesthetic purposes—such as UV varnish for added protection, matte finishes for a premium look, or tactile elements like soft-touch or raised coatings that elevate brand experience.
Additional options include foil stamping or holographic overlays.
Step 4: Die-Cutting & Forming
Using precision die-cutting technology, we cut the printed materials into exact shapes and sizes. This is where custom features like windows, spouts, hang holes, and specialty folds are added.
Forming techniques ensure the packaging can hold, protect, and display the product as intended.
Step 5: Assembly & Sealing
Once cut and shaped, each package is assembled and sealed using heat, adhesives, or ultrasonic sealing—depending on the material and intended use.
Proper sealing preserves product integrity and often plays a role in child resistance or tamper evidence.
Step 6: Quality Control & Shipping
Every package undergoes rigorous quality control to check for consistency, seal integrity, and visual accuracy.
After passing inspection, items are packed efficiently and shipped using sustainable logistics whenever possible.
Ready to elevate your product with custom flexible packaging?
At Spectrum, we specialize in industry-specific flexible packaging solutions tailored to your needs, regulatory environment, and sustainability goals. It’s truly the future of smart, sustainable branding!
We combine high-impact design, efficient production, and material innovation to help your packaging work harder and look better.
Whether you’re launching a new product line or refining your current packaging, our team is ready to partner with you to create custom cartons that reflect your brand and meet your business needs.
Let’s talk packaging–contact us today.