Filling Spouted Pouches: What Co-Packers Need to Know

You Picked a Pouch—Now What?

Choosing a spouted pouch is a smart move, but filling and sealing are where success is won. Whether partnering with a co-packer or upgrading your own line, use this overview to match equipment and process to your product. For format fundamentals, start with the pillar guide.

1. Types of Spouted Pouch Filling Equipment

• Manual Systems: Great for pilots; up to ~10 pouches/min; often paired with hand heat-sealers.
• Semi-Automatic: 15–30 pouches/min; pneumatic or servo pumps; integrated capping and sealing.
• Fully Automated: 80+ pouches/min; automated loading, filling, sealing, capping, and labeling with inline QC.

2. Hot Fill vs. Cold Fill

• Hot Fill: Common for sauces, soups, cleaners; 170°F+; requires rated pouches; often needs cool-down tunnels.
• Cold Fill: Used for dairy, cosmetics, protein drinks; may require cleanroom or aseptic environments; preserves sensitive actives.

Match fill method to materials and fitments; see component basics in Fitments & Valves 101 and overall format strategy in the pillar page.

3. Sealing & Capping: Get It Right

• Validate seal strength and burst resistance.
• Dial in cap torque for consistency and safety.
• Consider nitrogen flushing for oxygen-sensitive products.
• Methods include ultrasonic welding and heat sealing.

4. What to Look for in a Co-Packer

• Experience with your viscosity and category.
• Certifications (FDA, SQF, GMP, etc.).
• Equipment compatibility with your fitments.
• Flexible batch sizes and clear traceability.

Bonus: Inline Features That Improve Efficiency

• Date coding and batch labeling.
• Vision systems for fill level and cap alignment.
• Checkweighers; inline sterilization or UV; reject stations.