Custom pouches offer a sleek, efficient, and modern solution for packaging everything from personal care products to industrial chemicals. But getting it right takes more than picking a size and sending in a logo. From seal types to material compatibility and branding real estate, every detail of your pouch design plays a role in how your product performs and how your brand is perceived.
At Custom Pak Illinois (CPI), we work closely with clients to design and deliver pouches that do more than just contain a product—they communicate quality, protect the formula, and optimize the customer experience. As a trusted name in pouch filling service and turnkey packaging, we’re here to break down what you need to know before starting your custom pouch journey.
1. Start with Product and Fill Volume
Before choosing a pouch style or material, you need to define what’s going inside. Is it a thin liquid, viscous gel, paste, or powder? Does it require exact dosing or single-use convenience?
CPI’s contract pouch filling team helps determine the right pouch size based on:
- Product viscosity and flow characteristics
- Desired fill volume and portion control
- Storage requirements and shelf life goals
From single-serve sachets to industrial-size fill volumes, we ensure every pouch is sized for optimal performance and minimal waste.
2. Choose the Right Seal Type
Pouch sealing isn’t one-size-fits-all. Depending on your product type and usage context, the sealing method can impact shelf stability, tamper resistance, and user convenience.
CPI offers several sealing options as part of our contract packaging services, including:
- Heat sealsfor long shelf life and secure closure
- Tear notchesfor single-use pouches
- Zipper or reseal sealsfor multi-use applications
- Spouted closuresfor controlled dispensing
We evaluate product behavior, consumer habits, and industry standards to recommend the best seal for your application.
3. Understand Material Compatibility
Your product’s chemical makeup will determine which materials can be safely used without interaction or breakdown. CPI specializes in working with multi-layer, high-barrier films that withstand moisture, oxygen, UV exposure, and chemical volatility.
For example:
- Flammable or aggressive chemicals may require foil laminates or high-barrier structures
- Heavier products benefit from reinforced or gusseted structures
Our contract pouch filling and contract sachet filling processes are built to ensure material compatibility from day one—avoiding costly failures down the line.
4. Maximize Your Branding Space
Pouches offer a wide canvas for creative branding—but only if you plan your layout right. With CPI, you can customize your pouch design to include:
- Front and back full-color artwork
- Transparent windows or matte finishes
- Branded spout or cap color options
- Printed dosage instructions or regulatory language
Our team can work with your designers—or bring in our own—to ensure your pouch doesn’t just protect your product, it sells it.
Let’s Build the Perfect Pouch—Together
At Custom Pak Illinois, we make designing and producing custom pouches simple, strategic, and scalable. Reach out today to talk with our team of experts and explore how our pouch filling service, material expertise, and design support can bring your next product to market—faster, smarter, and with full confidence.
