types of flexible packaging

Types of Flexible Packaging + Uses and Benefits

Types of Flexible Packaging

Flexible packaging is a top choice across industries like food, healthcare, personal care, cannabis, and everyday consumer products, with popular types including pouches, films, bags, and wraps.

Packaging does more than just protect products; it shapes brand perception, preserves freshness, supports regulatory compliance, and streamlines operations. 

The right flexible packaging will help you reduce costs, minimize waste, and get your products to market faster—while complying with regulations and maintaining shelf appeal. 

Familiarity with the main types of flexible packaging will help you choose the right one for your products.

Stand-Up Pouches

Stand-up pouches are a type of pouch packaging that stands vertically thanks to a bottom gusset.

stand up flexible pouches

These are among the most popular types of pouch packaging because of their versatility, ease of display, and cost-effective shipping. You’ll find stand-up pouches everywhere, from snacks and supplements to cannabis. They can be designed with resealable zippers, hang holes, and custom finishes.

Cannabis brands often prefer stand-up pouches for edibles or infused pre-rolls. With child-resistant zippers and tamper-evident seals, stand-up pouches can also be made to meet compliance requirements without sacrificing shelf appeal. 

Mylar Bags

Mylar bags are high-barrier pouches made from a special plastic that’s ideal for preserving freshness and potency.

flexible mylar packaging bags

Thanks to their light and moisture-blocking capabilities, Mylar bags are widely used across various industries such as cannabis flower, concentrates, and edibles. They're also used in food, supplements, and powdered drink mixes. They can be heat-sealed or equipped with zippers and customized with windows, matte finishes, and high-definition graphics. 

Durability and a wide range of design possibilities make custom Mylar pouches a popular choice for brands looking to protect their products while creating an attractive, consumer-friendly package.

Child-Resistant (CR) Pouches

Child-resistant pouches help brands meet strict child-resistant packaging requirements while keeping the products accessible to adults.

child resistant flexible pouches

They’re widely used in pharmaceuticals, household chemicals, nutraceuticals, and tobacco products to ensure safety and prevent accidental access by children. Their versatile design makes them suitable for securely packaging medications, detergents, supplements, and nicotine products across various industries.

They often include certified zipper closures or push-and-turn features. They're also essential for THC-containing products like flower, concentrates, and gummies.

Sachets and Single-Serve Packets

Sachets are small, sealed, flexible packages used for single-use applications.

These are popular for powders, sample-size edibles, lotions, and drink additives. Sachets are lightweight and economical, perfect for promotions or first-time consumer trials.

In cannabis, they’re used for microdose edibles, daily supplement packs, or infused coffee. They're also ideal for subscription boxes and wellness kits. 

Sachets offer convenience and portion control, making them a favored choice in industries such as cosmetics, pharmaceuticals, and food service, where precise dosing and easy portability are important.

Wrappers and Flow Wraps

Flow wraps are flexible sheets sealed around a product using horizontal or vertical wrapping machines.

flexible flow wrappers for products

Often seen around snack bars, infused chocolate, or individual pre-rolls, flow wraps offer speed, branding potential, and excellent barrier protection.

They're best used when products have uniform shapes and high-volume needs. They’re common for both everyday consumer products and cannabis SKUs (stock-keeping units).

Sachets also offer convenience and portion control, making them a favored choice in industries such as cosmetics, pharmaceuticals, and food service, where precise dosing and portability are important.

Shrink Sleeves and Labels

Shrink sleeves and flexible labels allow brands to wrap graphics around jars, bottles, and cans.

They wrap tightly around containers, offering full-color, 360-degree branding without costly custom printing. Ideal for seasonal or limited-edition items, they provide both branding flexibility and tamper-evident protection.

Shrink sleeves and flexible labels are popular for everyday consumer products like personal care, household cleaners, and packaged foods. They’re also a great option for products that come in rigid containers (like beverages or tincture bottles) but still want branding flexibility. 

Lay-Flat Pouches

Lay-flat pouches (also called pillow pouches) are simple, sealed bags that are ideal for low-profile products.

lay flat flexible pouches

Their compact design makes them easy to stack and ship, helping reduce storage and transportation costs. Their airtight seals and multi-layer materials help preserve freshness and protect against moisture and oxygen. 

Lay-flat pouches are commonly used for food items like snacks, single-serve gummies, and sauces, as well as personal care products, pharmaceuticals, and pet treats. In cannabis applications, they’re perfect for single-serve gummies, pre-ground flower, or vaporizer accessories. 

Because lay-flat pouches use less material, they’re often a more cost-effective option for lower-margin products. They can be customized with tear notches, resealable zippers, and clear windows to enhance convenience and product visibility.

Retort Pouches

Retort pouches are heat-treated flexible packages used for shelf-stable foods and beverages.

They are commonly used for ready-to-eat meals, soups, sauces, pet foods, and juices because they can withstand high-temperature sterilization, which kills bacteria and extends shelf life without refrigeration. The pouch is filled, sealed, and then heated in a retort (a type of pressure cooker), allowing the contents to remain safe and fresh for months or even years.

In the cannabis industry, retort pouches are starting to be explored for shelf-stable beverages and infused ready-to-drink products, offering a convenient, lightweight, and portable alternative to cans or glass bottles. Their ability to preserve flavor, potency, and safety makes them an attractive option for new product formats that require long-term stability.

Custom Cartons and Rigid-Flexible Hybrids

Some products benefit from combining the strength of boxes with the efficiency of flexible films.

For example, a rigid box with a flexible pouch insert adds structure to delicate products while keeping material costs down. This is common in gift sets, premium flower packaging, and vape starter kits.

This hybrid approach offers both visual appeal and practical protection, making it a smart choice for brands seeking a balance of form and function.

Monolayer vs. Multilayer Materials

Monolayer packaging uses a single material, while multilayer combines different materials to enhance performance.

Monolayer packaging uses a single material: Typically made from polyethylene (PE) or polypropylene (PP), monolayer films are simpler and more cost-effective to produce. They are easier to recycle but generally provide limited protection against moisture, oxygen, and light, making them best suited for products with shorter shelf lives.

Multilayer combines different materials to enhance performance: By layering materials such as polyethylene terephthalate (PET), aluminum foil (AL), and polyethylene (PE), multilayer structures create strong barriers against moisture, oxygen, and light. This combination extends product shelf life and improves durability. On the flip side, it is more challenging to recycle due to the mixed materials.

Choosing between monolayer and multilayer materials depends on the specific needs of the product, including shelf life, protection requirements, and sustainability goals.

Real-World Applications Across Industries

Flexible packaging supports everyday consumer product brands, including:

  • Snack foods: Chips, nuts, and dried fruit in stand-up or flat pouches
  • Pet products: Treats, supplements, and food in resealable bags
  • Supplements: Powdered and capsule products in sachets or pouches
  • Drink mixes: Single-serve packets and multi-serve pouches
  • Household cleaners: Concentrated liquids or powders in spouted pouches
  • Personal care: Shampoo, lotion, and wipes in flexible sachets or pouches
  • Frozen foods: Vacuum-sealed bags for vegetables and prepared meals
flexible branded packaging

Flexible packaging also serves a wide range of cannabis product types:

  • Flower: Mylar bags or glass jars with flexible labels
  • Edibles: Stand-up pouches, flat pouches, or flow wraps
  • Pre-rolls: Child-resistant pouches or wrappers
  • Concentrates: POP-VAC containers with shrink sleeves
  • Beverages: Shrink labels or pouches with tamper evidence

How Flexible Packaging Providers Improve Competitiveness

Flexible packaging providers help brands stay competitive in several ways.

Faster Lead Times

Domestic flexible packaging production allows for quick turnaround times, so packaging arrives in days rather than months.

Low Minimum Order Quantities

Brands order only what they need, keeping inventory lean and protecting profit margins.

Regulatory Expertise

Flexible packaging specialists provide options that meet compliance requirements across evolving markets, supported by expert guidance.

Collaborative Design Process

Providers offer flexibility to customize form factors, finishes, and labeling to create packaging that stands out on the shelf.

Cost Optimization 

Flexible packaging companies provide opportunities to responsibly offshore production when appropriate, reducing long-term costs while maintaining supply chain diversity.

Sustainability Improvements

Responsible packaging companies offer recyclable and recycled options utilizing clean post-consumer waste (PCW) plastic. Sustainable packaging is a trend that’s being implemented by leading companies. As one key example, Amazon used flexible packaging for 50% of shipments in 2023, replacing most padded bags with recyclable paper mailers to reduce waste.

Whether launching a new product or entering new markets, flexible packaging solutions help ensure packaging supports growth without causing delays or added complexity.

Embrace the Advantages of Flexible Packaging

Flexible packaging helps cannabis and everyday consumer product brands stay agile, efficient, and connected to their customers. From mylar bags to sachets and child-resistant pouches, understanding your options will help you make informed decisions that protect your margins and elevate your customers’ experience.

Leading flexible packaging providers offer quick delivery, let you order small amounts to avoid excess inventory, and offer expert help to meet regulations. Custom designs make your brand stand out, and smart offshore choices typically lower costs over time. These benefits will help you launch products faster so you grow smoothly without delays.

Dustin has been active in the legal cannabis industry since 2015 and led the development of North America's largest manufacturer of child-resistant pouches from 2017 to 2021. At Vert, Dustin and his team leverage his deep knowledge in digital packaging and supply chain optimization to assist emerging CPG operators. His expertise helps accelerate the launch of new products and brands, significantly reducing both time and costs associated with market entry.

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