In business, every brand aims at maximizing efficiency when developing a product. The efficiency is determined usually by the cost and packaging design as per brand guidelines. B2B buyers in food, personal care, supplements or the industrial sector face another decision of roll stock or pre-made pouches or bags. Both are efficient in their own production scale, machines, flexibility of design and budget.
Knowing how roll stock film packaging compares to bags helps understand the operations involved in a brand and its processes, fulfilling its objectives. In this article we will dive into both formats so that you can truly understand your manufacturing capabilities, goals for the supply chain, and long term strategy for packaging.
What is Custom Roll Stock?
Roll stock that is custom made refers to printed and laminated flexible packaging film that is provided in rolls and ready to be loaded into form-fill-seal (FFS) machines. Using this type of machine, the pouch or bag is shaped on the location where it is packed, then the pouch or bag is filled with material before sealing everything off in one process.
Companies that use roll stock film tend to have fully automated filling lines or work with co-packers that do. This format is particularly preferred in fast-paced areas of production where uniformity and speed are critical.
Roll stock film packaging is often employed for products like snack foods, pet treats, powdered supplements, and coffee, among others.
What Are Pre-Made Bags?
As the name suggests, pre-made bags are made, shaped, and sealed (except for the top seal) by a packaging supplier and sent to the brand ready to be filled. Clients are only needed to fill the bags manually or with a semi-automatic machine and seal them.
These can include stand-up pouches, flat pouches, spouted pouches, and gusseted bags. Businesses that lack the ability to fully automate processes prefer pre-made formats due to greater control over smaller batches and a desire to use more premium packaging styles.
Comparing Custom Roll Stock and Pre-Made Bags
Both serve critical functions in the industry, although they serve different purposes. Let’s explore the primary differences.
Cost Efficiency and Production Scale
Custom roll stock is more economical when it comes to larger production runs. Because the bags are made on the premises, the cost for each unit is lower. Rolls are also more cost-effective in shipping and storage space because they take up less space than boxed pre-made bags.
The labor and production costs are higher for pre-made bags. These bags are best suited for small to medium runs or for brands that do not require high-speed automation and are low on budget.
If your facility uses FFS machinery, roll stock film packaging can reduce operational costs significantly over a period of time.
Speed and Automation
With FFS machines, roll stock enables faster production. Brands can produce thousands of packages per hour, maintaining a consistent output. This is ideal for fast-moving consumer goods (FMCG) and high-demand products.
Pre-made pouches slow things down for manual or semi-automated sectors. However, they offer flexibility and control, which may be beneficial in product lines with many SKUs or seasonal variations.
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Design and Customization
Both formats allow high levels of customization in terms of materials, finishes, and printing. However, pre-printed rollstock enables effortless consistent branding across large batches dynamically undergoing brand changes.
Pre-made bags are easier to customize with regards to shape and structure, such as adding zippers, spouts, die-cut windows, and bottom gussets. If the brand’s packaging is one of the primary factors that differentiates the product on the shelf, pre-made options might be more advantageous from an innovation standpoint.
Combining both keywords into one sentence is like stating: “Custom roll stock and roll stock film packaging enable high-speed branding with full-surface graphics, particularly when uniformity across large quantities is important.”
Material Options and Eco-Friendly Practices
Both roll stock and pre-made bags can be made from a variety of materials, including those that are recyclable, compostable, or made from post-consumer recycled (PCR) material. Roll stock tends to have a greater efficiency ratio in terms of raw material consumption, which leads to decreased packaging waste.
Because of the rigid construction, pre-made bags are generally thicker and may require an increased amount of material. At the same time, adding convenience features like resealability or spouts is easier.
B2B buyers trying to fulfill some sustainability objectives will want to ask regarding mono-material construction, recyclable inks, and energy-efficient laminates, which are available for both types of packaging.
When Custom Roll Stock is the Best Option
A business may consider custom roll stock if they:
- Already have (or plan to install) speed automated packaging lines.
- Operate a few core SKUs in large volumes.
- Need to lower unit packaging cost.
- Demand high consistency and fast time-to-market.
- Focus on operational effectiveness with less workforce involvement.
Contract manufacturers, large scale food processors, and brands selling supplements who operate multiple shifts and require consistent throughput are excellent examples of businesses that are well-suited to roll stock.
When Pre-Made Bags Are the Best Option
These bags best apply when:
- Trial SKUs or new products are introduced in smaller sized batches.
- Flexible packaging is done manually, or by semi-automated fillers.
- Premium shelf appeal and product presentation are equally top priorities.
- Custom spouts or stand-up gussets need to be added.
- Filling is done by a co-packer who does not have FFS capabilities.
These niche and premium pre-made options abound where intricate details design take precedence over unit cost and the business is agile enough to handle seasonal or short run packaging.
Conclusion: Which Flexible Packaging Format is Best for Your Brand?
The decision between custom roll stock and pre-made bags is not a question of one being superior; it is about what best suits your production, branding goals, and type of product.
- If you are increasing your production, restraining costs, or consolidating SKUs, roll stock film packaging will give you speed and consistency like no other.
- If your brand is focused on shelf presence, versatility, and agility, then pre-made bags have a high impact aesthetically and offer greater complexity.
Most brands prefer a combination of both formats throughout their product lines due to varying growth stages, packaging equipment, and marketing objectives.
Strategic foresight dictates that you choose a packaging partner who understands both sides of the coin: roll stock and pre-made bag production. They are in the best position to help you from an operational standpoint to make choices that optimize efficiency, design, and function.