The difference between stand-up pouches and flat pouches

The key difference between stand-up pouches and flat pouches lies in their construction and functionality. Stand-up pouches have a stable base that allows them to stand upright on their own - ideal for display on shelves or at points of sale. Due to their increased filling volume, they are particularly suitable for larger products or, for example, refill packs, such as for foods, personal care items, or household goods. If required, they can be customized with Euro slots or zippers.

Flat pouches, on the other hand, are a more compact, flatter packaging solution that is particularly suitable for smaller or flat products such as samples, spices, spare parts, or cosmetic items. Depending on requirements, they come with a 2- or 3-side seal: with a 2-side seal the pouch is sealed on two sides, while the bottom is folded and the top remains open and is closed after filling - this variant is well-suited to simple filling processes and is primarily used for small flat pouches. The 3-side seal is mainly used for large flat pouches, as these are often made from multiple webs of material. Flat pouches can also be equipped for the point of sale with Euro slots and additional customizations. The choice between stand-up and flat pouches ultimately depends on product type, desired presentation, and logistical requirements.

The advantages of stand-up pouches

Stand-up pouches combine advantages such as functionality, design variety, and sustainability. They are not only particularly efficient in manufacturing and logistics, but also offer the highest product safety and versatile presentation options - whether in brick-and-mortar retail or e-commerce.

The most important benefits at a glance:

• Material and resource efficiency: Up to 95% less material usage compared to rigid packaging.
• Low storage and transport costs: Low volume saves storage, transport, and disposal costs.
• Excellent product safety: Outstanding barrier against moisture, oxygen, and UV.
• Reclosability: Optional zipper for longer freshness after opening.
• Attractive product presentation: Self-standing, fully printable, and POS-optimized.

Stand-up pouches – the most eco-friendly and safest packaging

The most important task of a primary packaging - such as the stand-up pouch - is to reliably protect the packaged product. Especially for food, sensitive contents must be protected from external influences such as oxygen, moisture, and UV radiation. At the same time, the packaging itself must not allow aromas to escape - an essential factor for aroma-rich products like coffee or tea.

At the same time, the demand for sustainable packaging solutions is growing - both from consumers and through legal requirements. Modern packaging must therefore not only protect, but also be environmentally friendly and recyclable. packaging warehouse offers tailored solutions for this: our range extends from premium high-barrier films for maximum product safety to recyclable barrier papers from innovation leader Koehler Paper. In this way, we combine product protection and sustainability in flexible packaging - individually tailored to your product.

Manufactured in Germany – ISO 9001 certified

Our stand-up and flat pouches are produced exclusively in Germany - in compliance with the highest quality and safety standards. This not only ensures short delivery routes and particularly flexible production and delivery times, but also meets strict social and environmental standards. Our plants are HACCP certified and undergo regular recertification to guarantee continuous product safety. In addition, we are ISO 9001 certified by DQS - proof of our consistent quality management and our commitment to supplying you exclusively with high-quality packaging solutions. This way, you benefit from predictable quality, reliable delivery capability, and production you can always rely on.

Printing technologies – order small and large quantities

For printing our stand-up and flat pouches, we offer two proven processes: digital printing and flexographic printing. With both technologies we print on the reverse side. The image is applied to the back of the film and then protected by lamination - ideal for long-lasting color brilliance and abrasion resistance. We print on high-quality films made of BOPP, MDO-PE, or PET, optionally with matte or glossy finishes. Both digital toner and flexo inks are fully certified for food contact. Digital printing is particularly suitable for small to medium runs starting at 250 units and enables fast production within 10–14 working days - without plate costs. Flexographic printing is ideal for larger quantities and offers the option of implementing special colors such as Pantone—however, additional costs are incurred for the required plates.

Pouch converting & component selection – zipper, Euro slot & more

After lamination, the actual pouch converting takes place. The desired flat or stand-up pouch is formed from the printed and laminated film web. Depending on the pouch size, we manufacture these either from a single web or - especially for very large formats - from two or three separate webs. All sides and the bottom are precisely sealed, and the desired components are integrated. On request, we equip the pouches with practical extras such as reclosable zippers, tear notches, or a Euro slot. Flat pouches can be sealed on two or three sides. Our standard is the single-track zipper; for powder products we can optionally install a hook-and-loop zipper. All pouches are tested for leaks during production according to ASTM F2096 and carefully documented.

Stand-up pouches in your desired format

For your packaging we offer six fixed stand-up pouch formats that are particularly cost-effective thanks to our gang-run process:

• 100 ml – 90 x 60 x 160 mm

• 250 ml – 110 x 70 x 185 mm

• 500 ml – 140 x 80 x 210 mm

• 750 ml – 160 x 90 x 250 mm

• 1000 ml – 190 x 100 x 265 mm

• 1500 ml – 210 x 110 x 295 mm

Beyond that, you can of course also order custom stand-up pouch sizes precisely matched to your product. This allows you not only to define exact fill quantities but also to realize oversized formats up to a height of approx. 600 mm. We always calculate flat pouches on an individual basis - perfectly tailored to your requirements and your product.

PE mono films

Our stand-up pouches made from PE mono films are likewise a sustainable and versatile packaging solution and are, of course, recyclable and PPWR-compliant. The specially developed film composites feature an integrated EVOH barrier that offers high protection against oxygen and water vapor (OTR and WVTR ≤ 1), thereby reliably extending the shelf life of sensitive foods. Available in white (95 and 125 µm) as well as transparent (95 and 125 µm), they meet the highest standards of quality, stability, and printability. The pouches offer good tearing properties - though not quite as smooth as PP mono films - and can be individually designed in matte or glossy finishes. Our PE mono films thus combine sustainability, product protection, and attractive presentation options, making them the ideal choice for manufacturers who rely on modern, recyclable packaging.

Use as primary or secondary packaging

Our stand-up pouches, flat pouches, sachets, and roll stock are certified for direct food contact and are therefore fully suitable as primary packaging. Whether solid, pasty, or liquid foods - our pouches provide a safe and hygienic packaging solution. Vacuum sealing or filling under protective atmosphere is also possible, ensuring optimal freshness and shelf life for your products.

Beyond that, our flexible packaging is equally suitable as secondary packaging. It not only protects the product from external influences but also provides an appealing presentation at the point of sale. Typical areas of application, apart from food, include technical components, cosmetic products, textiles, or non-food items of all kinds.

Stability even for large fill volumes

Even for larger packaging sizes from 1,000 ml, we offer reliable solutions made from particularly robust materials. In our standard range, for example, we offer a 146 µm PP mono material. Thanks to the integrated CPP inner layer, this material has significantly increased stability and is optimally suited for voluminous or heavier fill goods.

To further increase load capacity, we have specially adapted our doypack sealing tools for large formats. This further strengthens stability, especially in the typical risk areas of a doypack.

For applications with very high fill weight or special requirements, we also offer LLDPE films. These feature excellent mechanical properties and ensure maximum durability - even for bulk packaging or demanding transport and storage conditions.

Another advantage: the width of the seal seams can be flexibly adjusted. Our standard dimension is 7.5 mm, but can be increased to 15 mm if required. This ensures absolutely secure and tight packaging even for heavy or bulky contents.

Stand-up pouches - easy to fill & seal

Our stand-up pouches can be supplied with the zipper closed or open. If the zipper is delivered in the open position, the pouch is usually shaped with the help of compressed air before filling: it is placed over a plastic mandrel, from which a short burst of air inflates the pouch and makes it dimensionally stable.

Filling follows - manually, semi-automatically, or fully automatically, depending on requirements. After filling, the zipper usually remains open, while the final seal at the top is made with a heat sealer. Depending on the material type, the sealing temperatures required for this are between 90 °C and 170 °C.

For efficient processes, we also provide the right equipment: with a semi-automatic sealing machine available through us, all common materials can be sealed reliably - at a capacity of up to 20 pouches per minute.