When it comes to flexible packaging, pouches offer more than convenience—they’re a smart, scalable solution for products that demand durability, shelf appeal, and cost efficiency. At Custom Pak Illinois (CPI), we help clients make the most of their packaging through expertly executed pouch filling service options and tailored support from concept to distribution.
But successful pouch packaging starts long before the filling line. If you’re planning a new pouch-based product, here are the key design considerations to keep in mind—and how we guide you through every step.
1. Material Selection Matters
Choosing the right pouch material is critical for both performance and compliance. At CPI, we offer a range of materials to match your product’s chemical makeup, viscosity, and usage environment.
For household products, barrier films help lock in volatile compounds. For industrial liquids, we offer puncture-resistant laminates. And if you’re working with flammable liquids, we’ll help you meet packaging safety standards without compromising functionality.
2. Size and Shape that Fit your Use Case
Pouches come in all shapes and sizes, from single-serve sachets to large-capacity refill pouches. We help clients determine the right volume and shape based on product type, user behavior, and distribution goals.
Need a travel-size option for a retail launch? We’ve got it covered. Running a refill program for high-volume cleaners or gels? We’ll help you design a custom pouch that minimizes material waste while maximizing storage efficiency.
Through our contract packaging services, we align form with function to ensure your pouch isn’t just practical—but also fits seamlessly into your supply chain.
3. Closure Systems that Enhance Usability
Pouch closures do more than seal—they define the user experience. We offer a variety of options including:
- Heat-sealed edges for tamper resistance
- Tear notches for easy opening
- Spouts and fitments for precision dispensing
- Resealable zippers for multi-use functionality
Depending on your product’s flow properties and end use, we’ll help you select a closure that supports clean application and reduces mess. Our co packing solutions are engineered to enhance user satisfaction, reduce waste, and protect your product through its entire lifecycle.
4. Branding and Labeling
Your pouch is a marketing tool. We help clients make it count with bold, clear branding and compliant labeling. Whether you’re printing directly on the pouch or using adhesive labels, we’ll ensure your design reflects your identity and meets regulatory guidelines.
As a packaging services company with deep experience in regulated markets, we make sure your branding works in tandem with function—so your product looks good and performs even better.
5. Integration with Turnkey Support
Design is just the beginning. When you partner with CPI, we take your pouch project from concept to shelf through our turnkey private label and contract packaging service programs. That includes formulation support, material sourcing, label design, contract filling services, and distribution—all handled by one experienced team.
We eliminate the hand-offs and guesswork that come with using multiple vendors. The result: a faster, more reliable path from idea to finished product.
Let’s Create the Right Pouch for Your Product
Designing a custom pouch involves more than picking a bag off the shelf. At CPI, we bring decades of pouch filling contract packaging experience to help you make strategic decisions that support your product goals—from material and closure to branding and filling.
Contact us today to discuss your next pouch project. Whether you’re scaling up production, entering a new market, or launching a fresh brand, we’re here to help you design smarter, fill faster, and stand out on the shelf.
