Spout Pouches and Bag in Box
Solution
From Artwork to Finished Bag
The full converting route we run in house for a custom printed bag or pouch, from the file you send us to the cartons that leave the factory.
Why This Sequence Matters
Most packaging problems are not caused by the bag. They are caused by a step in the middle: a file that separates badly, a laminate chosen without asking what the product does to it, a bag made 3 mm off the machine spec. This page sets out the sequence we run so you can see where your decisions matter and where ours do. Colour printing, bag making, impressing, sealing and automatic sticking all run on the same line without interval, which is why the handover points below are the only ones that need your input.
Step by step
Each Stage and What Can Go Wrong
- Brief and Specification
A quote against a catalogue size is not a quote against your line.
We ask for the format, filled weight or volume, film structure if you already have one, print colours and destination port before pricing anything. - Artwork and Separation
Files built for offset do not separate cleanly for gravure and the first proof shows it.
Send AI, CDR, PDF or PSD with fonts outlined. We separate for gravure and flag any element that will not hold at the chosen colour count. - Cylinder Engraving
Cylinders are the one tooling cost in the job and they lock in the design.
Cylinders are engraved once the separation is approved. Confirm sizes and text before this point because changes after engraving mean new cylinders. - Gravure Printing
Colour drifts between the proof and the run when nothing is checked against a reference.
Up to 14 colours on spout pouches, 10 on stand up pouches, 6 on block bottom bags and 1 to 4 colours both sides on ziplock bags, all checked against the approved proof. - Lamination
Barrier chosen by price alone shortens shelf life or delaminates in the retort.
We laminate the structure your product needs, from PET/LDPE up to PET/AL/NY/RCPP, and tell you which one we are running before it starts. - Bag Making and Fitments
The bag runs on our machine but stalls on yours.
Bag making, impressing and sealing run in line. Spouts, zippers, valves, tear notches, hang holes and adhesive strips are fitted to the format you specified. - Inspection
A leak found by your filler is a leak found too late.
Seals and fitments are checked before packing, print is checked against the approved proof, and the run is inspected as a step in the process rather than at the end of it. - Packing and Export
Good bags arrive crushed or short.
Packed in export cartons, in roll or sheet where the format calls for it, and shipped to the port you nominate. Export experience covers North and South America, Europe, the Mid East and Africa.
Answers
From Artwork to Finished Bag — Questions
What do you need before you can quote?
Format, size or fill volume, film structure or the product and shelf life, number of print colours, quantity and destination port. With those six items we can price the job properly.
Who pays for the printing cylinders?
Cylinder engraving is tooling for your design and is quoted as a separate line. Confirm the artwork before engraving because changes afterwards mean new cylinders.
Can I get a sample before the production run?
Samples are available. Ask for them at the quotation stage so the schedule allows for approval time.
What file formats do you accept for artwork?
AI, CDR, PDF and PSD. Any original editable file is workable. Outline the fonts before sending.
What is the minimum order?
It depends on the format. Documented minimums on our products start at 20,000 pcs for bag in box, 30,000 pcs for block bottom bags and 50,000 pcs for flower sleeves. Ask for the minimum on your specific format.
How is the order packed for shipping?
Export cartons as standard, in roll or sheet form for some film formats. Tell us the destination port and any pallet or labelling requirement.
Start With the Specification
Send what you know: format, volume, product, colours, quantity, port. We will fill the gaps and quote against it.