Pouch packaging isn’t one-size-fits-all. The wrong pouch size or material can lead to poor performance, higher costs, or even product failure in the field. That’s why selecting the right combination of pouch filling service options is critical—especially for products in industries like personal care, industrial chemicals, and household goods.
At Custom Pak Illinois (CPI), we don’t just run machines—we act as a consultative contract packager, guiding you through every technical decision to ensure your packaging performs as well as your product. In this post, we break down the key considerations for choosing the right pouch size and material for your application, and how CPI helps you avoid costly mistakes.
Step One: Define Your Fill Volume and Product Type
The first—and most important—factor to consider is your product’s fill volume and formulation. Is it a liquid, semi-liquid, or viscous gel? Is it water-based, flammable, or reactive? Each of these factors directly affects pouch size, structure, and barrier requirements.
CPI’s pouch filling contract packaging capabilities cover:
- Small single-serve pouches for samples and travel-size formats
- Mid-sized packs for consumer goods like detergents and lotions
- Large industrial pouches for adhesives, lubricants, and specialty chemicals
As part of our contract pouch filling process, we evaluate product flow rate, viscosity, and chemical reactivity to match your product with the appropriate pouch structure and filling equipment.
Step Two: Choose the Right Material for Performance and Compliance
Different products require different barrier properties. CPI works with multiple material types—such as multi-layer laminates and high-barrier films—to ensure your pouch:
- Protects product integrity
- Withstands punctures, leaks, or chemical interactions
- Complies with industry and transportation regulations
For chemical-based products or flammable liquids, CPI uses specialized materials designed for durability, safety, and compliance. For personal care or health-related products, we focus on clarity, feel, and shelf appeal.
This consultative material selection process is one reason we’re trusted among top contract packaging services companies and known for our technical flexibility.
Step Three: Consider Usage Context and End-User Experience
Where and how the pouch will be used matters. Will the user need to pour, squeeze, or tear? Will it be stored vertically or packed flat? Is it a single-use format or multi-dose?
CPI helps you think through:
- Custom spouts, tear notches, and resealable zippers
- Hanging holes for retail display
- Friction-seal or heat-seal formats for tamper resistance
- Cap colors and branding options to improve recognition
These details are what turn generic co packing services into smart, user-centered co packing solutions. We optimize every part of the packaging so it not only protects the product but enhances usability.
Let CPI Help You Select the Right Pouch—Start to Finish
Choosing the wrong pouch size or material can cost you. Let our team guide you to the right solution with full-service contract packaging services and deep industry knowledge. Whether you’re packaging chemicals, creams, or cleaners, Custom Pak Illinois’s turnkey packaging programs ensure your product gets to market in packaging that works hard, looks great, and holds up under pressure.
Contact us now for more information.
