Case Study: Custom Fin-Sealed Lay-Flat Pouches for Phat Snax
- Client Overview:
- Phat Snax
- Industry: Snack
- Company Size: Small
Phat Snax is redefining the snack aisle with a mission to make America’s snacks better for you — without killing the flavor. Their products, like the Devil’s Cake, are high in protein, low in sugar, and made with real ingredients — no seed oils, no fake sugars, no artificial anything.
Built around nostalgia and performance, Phat Snax represents a new wave of “snack with purpose” brands — bridging indulgence and health in one bite. To match that vision, they needed packaging that looked as bold, clean, and professional as their product tastes.
*Images above show the finished product*
Challenge
As a growing snack manufacturer, Phat Snax needed packaging that looked like printed roll stock film used by national snack brands — but without investing in expensive flow-wrapper machinery. Traditional pouches lacked the fin seal and crisp structure that consumers associate with mainstream snack cakes.
Without that detail, the product risked appearing “small-batch” instead of “retail-ready.” The goal was to create a pre-formed pouch that achieved the look, texture, and feel of roll stock — down to the seal and serrated edge.
Solution
Brown Packaging engineered a custom pre-formed lay-flat pouch with a fin seal and serrated edge to emulate flow-wrapped film packaging. The film structure was chosen for moisture resistance, shelf stability, and tight product fit, ensuring that each Devil’s Cake looked uniform and professional.
To achieve a perfect balance between performance and brand expression:
Multiple non-printed prototypes were hand-built and tested to refine sizing and form.
Barrier materials were adjusted to maintain product freshness and flavor integrity.
Artwork was applied to the final production die line, with registration and seal placement fine-tuned for print accuracy.
The result captured the same polished, vibrant energy seen across Phat Snax’s branding — reinforcing their “better-for-you, no-compromise” message.
Implementation
The project moved from concept to production in under six weeks.
Weeks 1–3: Brown Packaging created and tested prototypes across several materials and dimensions.
Weeks 4–6: Finalized the structure, artwork, and production run.
Each phase emphasized communication, testing, and precision, with only minor size adjustments needed before production.
Outcome
The finished pouches delivered exactly what Phat Snax envisioned — a flow-wrap look in a flexible pouch that feels right at home on the snack aisle. The new design:
Loads and seals efficiently.
Preserves product freshness.
Elevates brand perception across retail and DTC channels.
Client Feedback:
“They look great!”
Results
✅ Achieved a national-brand presentation without major equipment investment.
✅ Enhanced brand trust and consumer appeal with professional flow-wrap visuals.
✅ Optimized material performance for product protection and shelf stability.
✅ Streamlined production process for repeatable runs and quick restocks.
Why It Matters
For a fast-growing snack brand like Phat Snax, packaging isn’t just a container — it’s part of the product experience. The right pouch helped them project scale, consistency, and confidence on par with larger CPG competitors.
Brown Packaging’s approach combined technical packaging expertise with brand-first thinking, ensuring Phat Snax could scale without sacrificing authenticity or presentation.
Project Contact
Alex Vom Steeg
Account Manager | Brown Packaging
📧 alex@brownpackaging.com | 📞 949-433-9078
1990 W Corporate Way, Anaheim, CA 92801
www.brownpackaging.com
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