There are five main steps to creating amazing custom printed stand up pouches.
- From the beginning, we discussed what the client was packaging.
- We then looked at what they were trying to accomplish with their stand up pouches.
- This was followed by the Artwork Guidelines needed for custom printing.
- Then we introduced a series of checks and balances so the client feels comfortable saying “GO”.
Now we get to the FIFTH and final step: where are the stand up pouches?
Normal lead time for custom printed stand up pouches is 4-6 weeks after artwork approval. Here is how the time breaks down.
Week 1
In week one, the plant will create metal printing cylinders. Each of the colors in your final artwork requires a printing cylinder. If you have red, blue, yellow, and black, that means you need a cylinder for each of these colors, or 4 in total. Keep in mind that these are one-time charges, so if nothing in your artwork changes going forward, you won’t have to purchase printing cylinders again. Or, if something does change after a run -- for example, if you forgot an ingredient or want to add a nutritional item and all of this information is printed in black -- all you will need is an additional black printing cylinder; you will not have to replace the other cylinders. This means making changes isn’t a huge undertaking.
So, once your cylinders are done after the first week, the plant should ink up the cylinders and make a basic film proof using the actual colors you’ve listed on your approved artwork. For example, if your artwork is of an image of a horse and barn, among other things, you should expect a film proof to be made that mimics your artwork and is made using the very colors that will be used in final production.
Depending on your time frame, some plants will take a picture of the film proof and email it, or, upon request, they can send you the film itself. Keep in mind that you will not be looking at a finished custom printed stand up pouch -- you will have a very thin piece of film. This is what is known as the “inner liner,” or the printed portion of your stand up pouch. Stand up pouches are made from multi-layer barrier film, and each of these layers serve a purpose. Often, an outermost layer is used for puncture resistance, barrier properties, and strength. The inner or one of the middle layers will be the printed inner liner, and the innermost layer will be the one that will be counted on to act as a sealing layer so when your pouch is sealed, it is this innermost layer that actually melts and bonds and keeps the pouch closed.
All of layers of film are laminated together which traps or locks in the printed layer, which protects it from being scratched, marred, or distorted in any way. As mentioned above, each of the different layers has a role in protecting the contents inside the custom printed stand up pouch. There are many different variables that play a part into the type of film used for each of these layers, such as the weight of the contents, what the contents are made of, how the pouches will be filled or stored or even transported, if you want to actually be able to see your product, etc. Multi-layer barrier film isn’t only or always 3 layers. Sometimes it is 5, 6 or even 7 layers thick depending on the application. Count on your packaging professional for guidance.
So, you’ve either physically received the printed film proof or seen a photo of it and approved it.
Weeks 2 through 3
During weeks 2-3, the inner liner will be printed and all of the other layers will be run as well.
Weeks 3 through 4
During weeks 3-4, everything will be laminated together and then converted into the finished pouch size, with features such as ziplocks, tear notches, and even hang holes applied.
(Possibly) Weeks 5 through 6
After 4 weeks, your pouches should be done. It is here that we recommend having some sent by courier or expedited service so you can show off your amazing printed stand up pouches to employees, distributors, and customers. Just a few hundred or a few thousand will prepare you for when the entire shipment arrives. Plan on 10 days to 2 weeks after the pouches are done for final shipment to your door.
In closing, while moving into a custom printed stand up pouch can seem like a daunting task, these 5 Steps should be helpful in reducing the anxiety and giving you the tools needed to communicate effectively with your stand up pouch supplier and most importantly, compete with the “Big Boys” in your particular industry…and win!