Lines by Product Type
Doypack and Flexible Packaging Filling: When It Is More Economical Than Bottles
Doypacks use less expensive material than bottles and take up far less space when empty packaging is transported. However, packaging machine output is lower, and seal-quality requirements are more stringent.
Packaging Economics
An empty bottle occupies volume, while doypacks arrive as rolls or flat stacks. For a manufacturer transporting packaging over long distances, this provides significant savings in logistics and warehouse space.
The tradeoff is speed. A rotary doypack machine typically produces from 30 to 90 packages per minute, while a PET line operates at thousands of bottles per hour. Doypacks are selected for a specific market segment rather than as a replacement for the primary format.
Where the Format Works Best
- Juices and Fruit Drinks
- Children's segment; doypacks with a straw or spout.
- Sauces and Pastes
- Convenient dispensing and product evacuation by the consumer.
- Household Chemicals
- Economical refill packaging for the primary bottle.
- Liquid Feed and Supplements
- Small portions and low packaging cost.
Flexible Packaging Formats
| Format | Volume | Equipment |
|---|---|---|
| Doypack with spout | 0.1-1 L | Rotary machine with premade pouch feeding |
| Sachet | 10-100 mL | Vertical form-fill-seal machine |
| Bag-in-Box | 3-20 L | Aseptic filler for bags with a dispensing tap |
| 25 kg bag | up to 25 kg | Weigh filling station with sewing or heat sealing |
FAQ
Can a hot product be filled into a doypack?
Yes, provided that multilayer laminated film rated for the filling temperature is used. The material is selected together with the packaging supplier.
Is a separate doypack line required?
Usually, yes. Product preparation is shared, but the packaging section is separate. This allows bottles and pouches to run in parallel.
What is the typical payback period?
An automatic doypack machine costs significantly less than a PET line, so this format is often used to test a new product niche without a major investment.
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