Exploring the World of Pouch Packaging Materials
Packaging is an essential aspect of product design, as it helps to protect the contents and enhance their shelf life. One of the most versatile types of packaging is pouches, which can be used for a wide range of products, from food items to personal care products. Pouches are lightweight, portable, and come in various shapes and sizes. They are also customizable, allowing businesses to showcase their brand with unique graphics and designs.
The material used to make pouches can significantly impact their functionality and performance. In this blog, we will explore the different types of materials used to make pouches and their benefits and drawbacks.
Plastic Pouches
Plastic is one of the most common materials used to make pouches. It is versatile, durable, and lightweight, making it an ideal material for packaging. There are several types of plastic films used in the production of pouches, such as polyethylene, polypropylene, and polyester.
Polyethylene (PE) is a widely used plastic film that is suitable for packaging food items, such as snacks, baked goods, and frozen foods. It is affordable, has excellent moisture and oxygen barrier properties, and is easy to print on. Polyethylene films come in different thicknesses, with high-density polyethylene (HDPE) being more robust than low-density polyethylene (LDPE).
Polypropylene (PP) is another type of plastic film commonly used to make pouches. It is more durable than PE and has a higher melting point, making it suitable for hot-fill applications. PP films offer good moisture and oxygen barrier properties and are resistant to punctures and tears.
Polyester (PET) is a strong, high-clarity plastic film that is suitable for packaging products that require high barrier properties, such as coffee, snacks, and dried fruits. It is also suitable for packaging products that require microwaveable or oven-able pouches.
Plastic pouches are customizable, allowing businesses to showcase their brand with high-quality graphics and designs. However, plastic pouches are not biodegradable and can contribute to environmental pollution. They also have limited heat resistance and are not suitable for high-temperature applications.
Paper Pouches
Paper is a natural and biodegradable material that is becoming increasingly popular for pouch packaging. Paper pouches are lightweight, portable, and eco-friendly, making them an ideal option for dry food items such as nuts, seeds, and snacks.
Paper pouches are typically made from kraft paper, which is a sturdy and tear-resistant material. They are also customizable and can be printed with unique designs and graphics. However, paper pouches are not suitable for products that require high barrier properties, such as liquids and perishable food items.
Aluminum Foil Pouches
Aluminum foil is a high barrier material that is commonly used for packaging perishable food items, such as meat, dairy products, and beverages. Foil pouches offer excellent moisture and oxygen barrier properties, preventing spoilage and extending the shelf life of the product.
Aluminum foil pouches are puncture-resistant and tamper-evident, making them an ideal option for high-value products. They are also heat-sealable, ensuring the contents remain fresh and protected from external factors.
However, aluminum foil pouches are not suitable for microwave or oven-able applications. They are also not biodegradable and can contribute to environmental pollution.
Biodegradable Pouches
As consumers become more environmentally conscious, biodegradable pouches are becoming increasingly popular. These pouches are made from materials such as corn starch, sugarcane, and other natural fibers.
Biodegradable pouches break down quickly in the environment, leaving no harmful residues. They are also suitable for food items and offer similar barrier properties as traditional plastic pouches.
However, biodegradable pouches are more expensive than traditional plastic pouches and have limited availability. They may also have lower barrier properties than other materials, making them less suitable for certain products.
Composite Pouches
Composite pouches are made by combining different materials to create a customized packaging solution. For example, a composite pouch might combine plastic and aluminum foil to create a high barrier pouch suitable for packaging liquids and powders. Composite pouches offer a range of benefits, such as increased durability, enhanced barrier properties, and improved product shelf life.
Composite pouches are customizable and can be printed with high-quality graphics and designs. They are also tamper-evident, ensuring the contents remain fresh and protected from external factors.
However, composite pouches are more expensive than traditional plastic pouches and may not be suitable for all products. The use of multiple materials in composite pouches may also make them more difficult to recycle.
Summary: Which Pouch Material Should You Choose?
In conclusion, the choice of material used to make pouches depends on the product being packaged, the required barrier properties, and environmental considerations. From plastic and paper to aluminum foil and biodegradable materials, there are several options available for creating the perfect pouch for your product. By understanding the benefits and drawbacks of each material, businesses can make informed decisions about the best type of pouch packaging for their products.
If you are looking for custom pouches, then contact Brown Packaging today to get started.
In 2026, sustainability is no longer just a trend—it’s a buyer expectation. Forest Stewardship Council (FSC) certification has become a key benchmark for responsible packaging, signaling that materials are sourced from responsibly managed forests. For packaging buyers, FSC certification is more than a compliance checkbox—it’s a brand value that influences purchasing decisions, retailer acceptance, and customer loyalty. What Is FSC Certification? The Forest Stewardship Council certifies that paper-based packaging materials are sourced from forests managed for environmental responsibility, social benefit, and economic viability. FSC Mix: Packaging contains a blend of FSC-certified and controlled wood. FSC Recycled: Packaging is made entirely from recycled fiber. FSC 100%: Packaging is sourced only from FSC-certified forests. Why FSC Matters to Buyers in 2026 Retail access: Many major retailers now require FSC-certified packaging. Sustainability goals: Aligns with corporate ESG and carbon reduction commitments. Consumer trust: Customers recognize the FSC label and view it as credible. Global compliance: Meets international sustainability regulations. How FSC Certification Strengthens Brand Value Differentiation: Stand out with certified sustainable packaging. Marketing advantage: FSC logos reinforce eco-friendly messaging. Risk reduction: Verified sourcing prevents greenwashing claims. Customer loyalty: Environmentally conscious buyers prefer certified products. Challenges in FSC Implementation Limited supply of certain FSC substrates. Higher costs compared to non-certified materials. Need for supplier audits and documentation. Packaging Solutions with Brown Packaging Brown Packaging partners with buyers to integrate FSC-certified materials into corrugated boxes, folding cartons, and retail packaging. Our solutions support sustainability while maintaining cost efficiency and protection. Contact us to strengthen your brand with FSC-certified packaging. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Consumer Insights on Sustainable Packaging. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Sustainability is now a top priority for packaging buyers. Retailers, regulators, and consumers are all demanding packaging solutions that reduce environmental impact without sacrificing performance. In 2026, buyers must balance eco-friendly materials, cost, and compliance to build programs that are both effective and future-ready. What Buyers Need to Know About Sustainable Packaging Regulatory pressure: Governments are enforcing stricter rules on recyclability and plastic use. Retail mandates: FSC certification and recyclable packaging are becoming standard requirements. Consumer expectations: Customers increasingly choose brands with visible sustainability commitments. Sustainable Material Options Recycled corrugated: High recycled content while maintaining compression strength. Compostable films: Suitable for select food and retail applications. Molded pulp inserts: Replace foam or plastic for protective packaging. Water-based coatings: Enhance moisture resistance without harmful chemicals. Balancing Cost and Performance Right-size packaging: Reduces material waste and shipping costs. Hybrid solutions: Combine eco-materials with corrugated for balance. Life cycle analysis: Evaluate true environmental impact, not just marketing claims. How to Evaluate Sustainable Suppliers Verify FSC, SPC, or ISO certifications. Request testing data for durability and recyclability. Audit supply chains for consistency and transparency. Ensure claims meet local and international compliance standards. Packaging Solutions with Brown Packaging Brown Packaging helps buyers implement sustainable packaging programs that balance cost, performance, and compliance. From recycled corrugated to eco-friendly coatings and inserts, we deliver solutions that meet 2026 sustainability goals. Contact us to explore sustainable packaging options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Packaging Sustainability Trends and Buyer Insights. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Choosing the right packaging material is one of the most important decisions buyers face. Single-material packaging offers simplicity and recyclability, while multi-material designs provide enhanced performance and protection. Understanding the trade-offs helps companies balance cost, functionality, and sustainability goals in 2026. What Is Single-Material Packaging? Single-material packaging uses one substrate—such as corrugated board, folding carton, or plastic—for the entire structure. Advantages: Easier to recycle and dispose. Lower material costs in many cases. Streamlined sourcing and inventory. Supports sustainability messaging. Disadvantages: Limited barrier protection. Less customization for fragile or complex products. May require added thickness for strength, increasing weight. What Is Multi-Material Packaging? Multi-material packaging combines two or more substrates—such as corrugated with foam, or paperboard laminated with film—to achieve specific performance outcomes. Advantages: Greater protection against moisture, oxygen, and impact. Allows for premium finishes and enhanced graphics. Ideal for fragile or high-value products. Customizable for unique supply chain conditions. Disadvantages: More difficult to recycle due to material separation. Higher cost and longer lead times. Complex sourcing and inventory management. When to Use Each Approach Single-material packaging: Best for products with low fragility, strong sustainability requirements, or cost-driven programs. Multi-material packaging: Best for high-value, fragile, or regulated products requiring advanced protection. Balancing Performance and Sustainability Buyers must weigh performance needs against eco goals: Use recyclable coatings to extend single-material performance. Choose hybrid designs that separate easily for recycling. Apply multi-material solutions only where risk of damage outweighs cost. Packaging Solutions with Brown Packaging Brown Packaging helps buyers evaluate when to use single- vs. multi-material packaging. Our team balances sustainability, performance, and cost to deliver solutions tailored to your supply chain. Contact us to explore the right approach for your products. References Forest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Sustainable Packaging Coalition. (2022). Design for Recyclability and Multi-Material Packaging Report. Retrieved from https://sustainablepackaging.org (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
One of the biggest challenges in sustainable packaging is balancing environmental responsibility with product protection. Buyers often worry that switching to eco-friendly materials means sacrificing durability or driving up costs. In 2026, new material technologies allow brands to meet sustainability goals without compromising strength or supply chain performance. Why Protection Still Matters Damaged products create more waste than packaging ever could. Returns increase logistics costs and carbon emissions. Retailers and e-commerce platforms expect packaging to deliver both sustainability and reliability. Eco-Friendly Material Options Recycled corrugated: Maintains stacking strength while reducing virgin fiber use. Molded pulp inserts: Cushion fragile items while replacing plastic foam. Water-based barrier coatings: Add moisture resistance without plastic films. Compostable films: Ideal for short shelf-life or single-use applications. Paper-based mailers: Replace poly mailers for e-commerce shipments. How to Balance Eco Goals and Protection Use right-sizing to reduce material volume while improving fit. Apply hybrid solutions (corrugated + pulp) for high-value goods. Conduct ISTA testing to validate protective performance. Match material choice to product fragility and supply chain conditions. Examples in Action Electronics: Molded pulp trays replacing EPS foam. Food and beverage: FSC-certified corrugated with recyclable coatings. Retail e-commerce: Recycled paper mailers protecting apparel. Packaging Solutions with Brown Packaging Brown Packaging develops eco-friendly solutions that protect products while meeting sustainability requirements. From recycled corrugated to innovative coatings, our team ensures you never trade protection for environmental impact. Contact us to explore eco-material options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Eco-Friendly Packaging Materials and Case Studies. Retrieved from https://sustainablepackaging.orgASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
In today’s competitive market, packaging affordability doesn’t start with cheaper materials — it starts with smarter design. Every score, fold, and insert decision affects not only how a box looks and feels, but how efficiently it’s made, shipped, and used. Structural engineering is the silent driver of cost efficiency — optimizing strength, space, and performance before the first sheet is ever printed. Why Structure Matters More Than You Think The most impactful cost savings in packaging rarely come from supplier discounts; they come from structural efficiency.A box that uses 10% less board but maintains the same compression strength directly reduces both material and freight cost. A redesigned insert that eliminates the need for secondary packaging saves time and labor at the line. Every cut line and fold path tells a story of cost, sustainability, and brand care — and when those align, affordability becomes part of your brand’s DNA. Designing for Efficiency, Not Excess In a market saturated with overbuilt packaging, engineering restraint is a competitive advantage. Structural teams now rely on 3D CAD modeling and virtual prototyping to simulate performance before production — identifying unnecessary material use and structural redundancies. Through precision die-line planning, engineers can improve sheet yield, reduce assembly time, and minimize void space — the dead air that drives up freight bills.It’s not about doing less; it’s about doing smarter. Balancing Protection and Presentation The temptation to “overprotect” products is common — especially in fragile or high-value goods. But protection doesn’t have to mean bulk. Strategic reinforcements, engineered fluting, and interlocking designs can maintain crush resistance and shock absorption while reducing total board weight. For e-commerce and shelf packaging alike, brands can achieve premium presentation with structural simplicity — a key to making packaging both sustainable and affordable. Prototyping to Prevent Waste Prototyping isn’t just for aesthetics — it’s a safeguard against costly production errors.With short-run sample testing and performance mockups, brands can evaluate fit, function, and protection early in development. Adjusting dimensions by fractions of an inch can save thousands in material waste and prevent rejected runs down the line. Smart packaging buyers now view prototyping not as an expense, but as a cost-control strategy that pays dividends in scale. How Structural Design Supports Brand and Budget Affordable design doesn’t mean compromising brand identity — it means integrating brand goals into structure. A well-engineered box reinforces trust, ensures product consistency, and communicates value through precision and fit. When structure, design, and production align, packaging stops being a cost and starts becoming a business asset. That’s where the real savings live — and where long-term brand equity begins. The Brown Packaging Difference At Brown Packaging, every packaging solution starts with structural intent — not guesswork.Our engineering and design teams collaborate to create packaging that performs across shipping, retail, and automation lines, balancing protection, brand visibility, and cost efficiency. We don’t cut corners; we cut waste.That’s how our clients achieve packaging that’s not just affordable — it’s engineered to perform. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. PMMI. (2024). Optimizing Structural Design for Packaging Efficiency. Packaging World. (2025). Engineering the Future of Cost-Effective Packaging. Smithers. (2025). Packaging Innovation and Material Efficiency Trends. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Every brand is feeling the squeeze — higher raw material costs, volatile freight rates, and a consumer base more price-conscious than ever. But cutting packaging budgets blindly can lead to damaged goods, compliance issues, and eroded brand value. Smart brands aren’t chasing cheaper boxes — they’re making smarter packaging decisions that balance performance, cost, and perception. The difference between saving money and losing value comes down to how you evaluate your packaging, not just what you pay for it. Beyond Unit Price: Understanding Total Packaging Cost A low unit price might look great on paper — until you factor in assembly time, damage rates, and freight efficiency. Smart packaging evaluation considers the total cost of ownership, including: Material yield (how efficiently sheets convert into boxes) Pallet and trailer utilization (freight optimization) Labor efficiency (ease of assembly or automation compatibility) Product protection (damage rates, replacements, and returns) When buyers assess all these metrics, the lowest-cost box often isn’t the best-value box. Material Selection That Saves in the Long Run Switching materials isn’t just about cutting cost — it’s about reducing waste and improving performance. For instance, moving from double-wall to a high-performance single-wall with better flute structure can cut weight and shipping cost without sacrificing protection. In folding cartons, substrate optimization — using a lighter caliper SBS or switching to coated recycled board — can yield savings that scale across production runs. And for rigid boxes, structural tweaks like thinner chipboard paired with strong wrap papers can preserve presentation while reducing material use. Every small change adds up when you scale across thousands of units. Design Efficiency: The Overlooked Cost Saver A smart structural design can eliminate cost before production even starts. Simplifying folds, reducing glue flaps, or reengineering inserts can cut assembly time and material waste. Modern packaging engineers use CAD-based dieline analysis to optimize layouts — ensuring maximum sheet yield and minimal offcut. For e-commerce and retail brands alike, right-sizing packaging improves shipping efficiency and reduces filler materials while maintaining the brand’s polished look. It’s not just design — it’s design that earns its keep Printing Smart: Matching the Process to the Purpose Not every job needs premium litho or complex spot varnishes. A good packaging partner matches print method to scale and brand intent: Flexo printing for high-volume, cost-efficient runs. Digital printing for short runs, personalization, and multi-SKU campaigns. Litho laminating for high-end visuals in rigid or premium retail displays. By choosing the right print method early, brands can avoid over-engineering — saving both time and money without compromising quality. Data-Driven Decisions: The New Standard for Packaging Buyers Leading companies now use data to guide packaging spend. Damage rate metrics, SKU-level freight analysis, and consumer perception studies all contribute to smarter choices. Smart buyers are no longer asking, “What’s the cheapest box?” They’re asking, “What’s the most efficient box that protects the product, ships well, and supports brand goals?” This mindset shift is what separates cost-cutting from cost control. The Brown Packaging Approach At Brown Packaging, we help brands make smarter packaging decisions by combining engineering analysis, supplier network leverage, and real-world testing. Our process aligns packaging performance with total cost goals — from box design to print selection and logistics. The result: stronger packaging, lower waste, and sustainable cost savings that scale with your business. Because in today’s market, smart packaging isn’t just a cost center — it’s a competitive advantage. References PMMI. (2025). Operational Cost Efficiency in Packaging and Logistics. McKinsey & Company. (2024). Total Cost of Ownership in Consumer Goods Packaging. Packaging World. (2025). Data-Driven Decisions in Packaging Sourcing. Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
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In today’s crowded marketplace, where consumers are overwhelmed with choices, establishing differentiation is crucial for any brand’s success. One of the most effective ways to stand out is through innovative and distinctive packaging. This blog post will explore strategies for leveraging packaging as a tool to differentiate your products in a saturated market. Understanding the Power of Packaging in Market Differentiation Packaging is not just a means to protect and contain a product; it’s a critical marketing tool. It communicates your brand’s message, values, and identity. In a saturated market, unique packaging can be the deciding factor that sways consumer preference and drives purchase decisions. Strategies for Differentiating Packaging Bold and Unique Design: Use eye-catching designs and color schemes that differentiate your product from competitors. Think outside the traditional aesthetics of your category to captivate attention. Incorporate unique shapes, sizes, or textures in your packaging design. Unconventional packaging can intrigue consumers and encourage them to take a closer look. Innovative Materials and Sustainability: Opt for innovative materials that not only protect the product but also align with emerging consumer preferences, like sustainability. Utilize eco-friendly materials, such as biodegradable plastics or recycled paper, to appeal to environmentally conscious consumers. Customization and Personalization: Offer personalized packaging options. This could range from personalized labels to customizable packaging designs. Limited editions and seasonal packaging can create a sense of exclusivity and novelty. Interactive and Smart Packaging: Integrate technology into your packaging, such as QR codes, AR elements, or NFC tags. This adds an interactive layer to your product, enhancing customer engagement. Use smart packaging to provide additional product information, tell your brand’s story, or offer a unique digital experience. Clear and Consistent Branding: Ensure your packaging clearly communicates your brand identity. Consistent use of logos, colors, and imagery helps build brand recognition. Packaging should reflect the brand’s personality, whether it’s luxury, playful, eco-conscious, or cutting-edge. Functionality and Convenience: Design packaging that adds functional value. For example, resealable or easy-to-open packaging can be a significant differentiator. Consider the end-user experience. Packaging that simplifies storage, usage, or disposal can offer an edge over competitors. Storytelling Through Packaging: Use your packaging to tell a story. This could be the history of your brand, the journey of your product, or the ethos behind your company. Storytelling can create an emotional connection with consumers and make your product more memorable. Market Research and Consumer Insights Conduct thorough market research to understand what resonates with your target audience. Stay updated with current trends in packaging and consumer preferences. Collect feedback on your packaging and continually refine based on consumer insights. Testing and Prototyping Before a full launch, test different packaging designs in focus groups or small market segments to gauge consumer response. Use prototyping tools to visualize and modify packaging designs efficiently. If you are interested in brand differentiation for your product and packaging, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
The packaging industry has undergone significant changes in recent years, with new technologies such as digital print revolutionizing the way packaging materials are produced. Digital print technology offers a cost-effective and efficient way to create customized packaging materials with unique designs and graphics, while minimizing setup time and cost. In this comprehensive guide, we will explore what digital print is in packaging, how it works, its advantages and disadvantages, and its various applications. Whether you are a business owner looking to create customized packaging materials for your products or a consumer interested in the latest packaging trends, this guide provides valuable information on the benefits and limitations of digital print in packaging. Overview: Digital Print Explained This blog explores the topic of digital print in packaging, including what it is, how it works, its advantages and disadvantages, and its various applications. The guide will be explained: What is digital print in packaging? How Does Digital Printing in Packaging Work? Advantages of Digital Print Disadvantages of Digital Print Digital Print Packaging Applications What is Digital Print in Packaging? Digital print in packaging is a printing process that uses digital technology to print high-quality graphics, images, and text directly onto packaging materials. Unlike traditional printing methods, which require expensive setup costs and long lead times, digital print technology enables businesses to create customized packaging materials quickly and cost-effectively. Digital print technology works by using specialized software to create digital artwork or designs that are then printed directly onto the packaging material. The digital printer uses inkjet or laser technology to apply the design or image onto the surface of the material. One of the key advantages of digital print technology is its ability to create customized designs, graphics, and text on a wide range of packaging materials, including paper, cardboard, plastic, and metal. This allows businesses to differentiate their products from the competition by creating unique packaging materials that stand out on store shelves. Digital print technology also offers greater flexibility and speed than traditional printing methods. Because digital printers do not require the use of printing plates, setup time is significantly reduced, and changes to the design can be made quickly and easily. This makes digital print technology ideal for short runs and small batch orders, which can be produced in a matter of hours or days. How Does Digital Printing in Packaging Work? Digital print technology works by using specialized software to create digital artwork or designs that are then printed directly onto the packaging material. The process involves several steps: design creation, file preparation, printing and finishing. Design Creation The first step in the digital print process is to create the design or artwork that will be printed onto the packaging material. This is done using specialized software such as Adobe Illustrator, Photoshop or special programs created by the machine manufacturer. The design can include images, text, and graphics, and can be customized to meet the specific needs of the packaging project. File Preparation Once the design is complete, it is saved in a digital format that can be read by the digital printer. The file is then prepared for printing by adjusting settings such as color and resolution to ensure that the final print is of high quality. Printing The next step is to print the design onto the packaging material. The digital printer uses inkjet or laser technology to apply the design or image onto the surface of the material. The printer can print a single design or multiple designs on the same sheet, depending on the size and shape of the packaging material. Finishing Once the printing is complete, the packaging material is finished according to the desired specifications. This can include cutting, folding, and gluing to create the final packaging product. Overall, digital print technology offers several advantages over traditional printing methods, such as offset printing. Unlike offset printing, which requires printing plates and complex setup processes, digital print technology does not require printing plates and has a much shorter setup time. This makes it ideal for short runs and small batch orders, which can be produced quickly and cost-effectively. Additionally, digital print technology allows for greater flexibility in design, as changes can be made quickly and easily without incurring additional setup costs. This allows businesses to create customized packaging materials with unique designs and graphics, which can help them stand out from their competitors on store shelves. Advantages of Digital Print in Packaging Digital print technology offers several advantages over traditional printing methods, such as offset printing, for producing customized packaging materials. Some of the advantages of digital print in packaging are: Customization Digital print technology enables businesses to create customized packaging materials with unique designs, graphics, and text. This allows companies to differentiate their products from the competition and create packaging that aligns with their brand image and values. Speed Digital print technology has a fast turnaround time, allowing businesses to produce customized packaging materials quickly and efficiently. This is particularly useful for businesses with time-sensitive promotions or seasonal products. Multi-SKU Printing It is quite ideal for companies to print digitally for multiple SKU products. This is because digital printing is much more flexible and efficient than alternative printing methods in adjusting to changing art work. Cost-Effective Digital print technology eliminates the need for expensive setup costs associated with traditional printing methods. This allows businesses to produce short runs or small batch orders cost-effectively. Sustainability Digital print technology produces less waste than traditional printing methods, making it a more sustainable option for packaging materials. Additionally, digital printing uses water-based inks that are more environmentally friendly than solvent-based inks used in traditional printing methods. High-Quality Digital print technology produces high-quality images and text, providing businesses with a way to create packaging materials that showcase their products in the best possible light. The technology uses advanced color management systems that ensure accurate color reproduction and sharp image quality. Flexibility Digital print technology allows for greater flexibility in design, as changes can be made quickly
RSC boxes are known for their efficiency and versatility, but their performance ultimately comes down to strength. Buyers often see numbers like ECT, BCT, and burst strength on specifications — but which tests matter most, and what do they actually measure? Choosing the right RSC depends on understanding how these tests translate to real-world shipping conditions. Edge Crush Test (ECT) What It Measures Resistance of corrugated board to edgewise compressive forces. Expressed in pounds per inch (e.g., 32 ECT). Why It Matters Directly tied to stacking strength and pallet performance. The most common metric used in North America for corrugated box strength. Limitations Only measures board strength, not the full box. Doesn’t account for humidity, handling abuse, or long-term compression. Box Compression Test (BCT) What It Measures Maximum load a finished box can withstand before collapsing. Accounts for box size, design, and board strength. Why It Matters Most accurate predictor of how an RSC will perform in stacking and pallet loads. Useful for optimizing board grades to reduce cost without risking damage. Limitations Requires lab testing of actual boxes. Not always practical for small-volume or custom runs. Burst Strength (Mullen Test) What It Measures Pressure required to rupture corrugated board by puncture. Historically the go-to test before ECT became standard. Why It Matters Still relevant for industries where puncture or tearing is a higher risk than compression (e.g., heavy parts, bulk industrial goods). Limitations Doesn’t reflect stacking strength. Often replaced by ECT in modern logistics. Translating Tests to Real-World Performance High-Volume E-Commerce: ECT rating is usually the key metric, especially for stacking in warehouses. Heavy Industrial Products: Burst strength may be more relevant if products are sharp or heavy. Palletized Loads: BCT is the best indicator, as it measures box and board performance together. Moisture & Humidity: None of the above tests fully account for water absorption — additional treatments or coatings may be necessary. Buyer Takeaway Look for ECT when evaluating basic strength requirements. Prioritize BCT if your shipments are palletized or stacked in warehouses. Consider burst strength if your products are heavy, sharp, or prone to puncture risks. Remember: lab tests are only part of the story — real-world conditions like humidity, handling, and long-term storage will also affect performance. References Fibre Box Association. (2023). Box Performance Standards. https://www.fibrebox.org TAPPI. (2024). Testing Methods for Corrugated Packaging. https://www.tappi.org Soroka, W. (2016). Fundamentals of Packaging Technology (5th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Regular Slotted Container Facebook Twitter LinkedIn Pinterest Relevant Posts