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Specification options for sealed soft pouches

A sealed pouch looks like the simplest product in a range and is one of the easiest to get wrong, because performance concentrates in two places: the film and the join. The brief should open with what goes inside, how long the unit stays submerged or exposed, and whether it sells on a retail card or packs inside a larger product.

Film choice decides most programmes. PVC is the cost floor and prints well, but it stiffens noticeably in cold conditions and carries a heavier compliance conversation in several markets. TPU costs more per metre, welds at different energy settings and holds flexibility down to freezing. Where the pouch must hold shape rather than only exclude water, a moulded EVA shell beats a thicker film.

Join geometry deserves as much attention as the film. A 6 mm weld looks tidier than a 12 mm weld, but peel strength rises with width and narrow welds curl sooner, so visual preference and mechanical requirement have to be reconciled before tooling is cut. Corner radius is the other quiet variable. Material behaviour is summarised under film, coating and laminate selection.

Cost drivers and MOQ for sealed soft pouches

Film is the largest material line, and gauge is the lever buyers underestimate. Moving from 0.25 mm to 0.40 mm TPU can add a fifth to material cost without feeling any better, while the same money on a moulded shell or a better closure changes perceived quality immediately. After film comes the closure, then tooling for dies and electrodes.

Printing is the second cluster. Film surfaces accept screen and UV print well but usually need a primer or corona treatment, and multi-colour artwork on a small part carries a setup cost that behaves like tooling. For several colourways, print one film lot and differentiate by trim, which keeps every colour on a single film minimum.

Minimums begin at 500 units per style per colour, reducing to 300 on repeat programmes once electrodes and dies exist. Sampling runs 6–10 working days, extending to 12–15 where a moulded shell or custom closure is commissioned, and mass production takes 35–50 days after written approval. Terms are T/T 30/70, quotations are returned in 24–48 hours, and dispatch is FOB Xiamen with EXW, CIF or DDP available. Tooling sits at USD 300–2,500, and the USD 50–150 sample fee is credited to your first bulk order.

These parts are light but bulky once packed, so carton efficiency usually decides whether landed cost is profitable or marginal. Plan against 28 CBM per 20GP, 56 CBM per 40GP and 68 CBM per 40HQ, and choose sea at 25–35 days unless a launch date forces air at 5–8 days; courier at 3–5 days covers samples. How quantity reshapes tooling amortisation is explained in our cost and quantity planning reference.

Closure systems, ingress ratings and retail presentation

An ingress rating is a claim, and claims need evidence. A pouch sold for use inside a larger bag does not need an immersion rating, and specifying one raises cost without changing the customer experience. Anything marketed for paddling or water sports needs a tested figure, and the rating on the packaging has to match the rating in the report.

Retail presentation changes the build more than most briefs allow for. A hang card needs a reinforced hole or a welded loop, shelf presentation favours a moulded shell that stands up, and e-commerce favours a flat pack that photographs cleanly. Carry closure and trim language across the family so it reads as one programme; our private label programme page covers how that is standardised. Small parts also pair well with coordinated soft pouches for cosmetics and accessories.