Here are five ways to reduce the cost of flexible packaging without sacrificing quality.
1. Buy in bulk
Larger quantities significantly lower the per-unit price — press set-up overheads and wastage are spread across more units. Always get quotes for bigger volumes to find the most economical order point. Quality impact: none — it's the same material, just bought in larger quantities.
2. Optimise material thickness
Choosing an optimum film thickness — enough to maintain stability and barrier properties — can cut cost meaningfully. Quality impact: none, as long as the barrier and stability are preserved.
3. Simplify the design
Fewer colours and simpler artwork use less ink and reduce cost, especially on large runs. Quality impact: a clean, simple design can still look premium and brand effectively.
4. Reduce wastage
Minimise production and storage losses; better filling or automatic form-fill-seal (FFS) machines cut labour costs too. Quality impact: precise production keeps quality intact while reducing waste.
5. Optimise the pack size
Right-size the pouch to remove excess empty space — though keep 15–20% headspace for filling and protection. Quality impact: a properly sized pack still protects and showcases the product.
Conclusion
Together, these strategies deliver real savings while keeping quality the same. One of the easiest wins is buying ready-stock pouches with bulk discounts — explore Sprinlock's range or order a free sample kit to compare.
