Lay-Flat Pouches

Although stand-up pouches offer many advantages for certain products, not all items benefit from these designs. Lay-flat pouches differ from stand-up pouches because the package lies flat rather than standing erect on a shelf. Because lay-flat bags use less material and are often easier to manufacture, they typically offer increased cost savings over many other bag styles.

At Caltex Plastics, we supply lay-flat pouches in various sizes and materials to serve a comprehensive product range, from cosmetics and personal care items to food and powdered drink mixes. These designs often work well as interior packaging for products that utilize a larger-size outer box or overpack later. Our team can help you choose an existing design or develop a custom solution to meet your packaging needs.

What Are Lay-Flat Bags?

Lay-flat bags — often called pillow pouches — are versatile, economical packaging solutions that perform various functions with numerous design enhancements. These bags utilize the most efficient packaging designs that call for minimal material. Caltex Plastics can manufacture lay-flat bags for either single-use or resealable purposes. Additional design options like hang holes and tear notches offer enhanced packaging functionality.

Materials We Use for Lay-Flat Packaging

Caltex Plastics manufactures lay-flat bags and pouches in a range of materials, including:

• Laminate: Laminated bags consist of multiple layers of material for enhanced protection against air, moisture, oils, light and other elements that can affect a product’s quality. We use numerous laminated materials in various thicknesses for our lay-flat bags, including foils, Mylar, electrostatic discharge (ESD) protective static shielding and moisture barrier.
• Poly: Poly bags are among the most popular packaging materials across a broad industry range. They’re a versatile, economical solution for products not requiring multiple layers for protection. We offer lay-flat poly bags made from low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE) and high-density polyethylene (HDPE) in various colors and thicknesses ranging from 0.5 to 8 mils.

Benefits of Lay-Flat Pouches

Depending on the product type, distribution and marketing, lay-flat pouches offer many benefits over other bag designs. Several examples include:

• Cost savings: Lay-flat pouch designs are among the most cost-efficient plastic bag styles, offering significant savings over most other options on the market. Less material per bag also increases cost efficiency during transport and storage.
• Marketability: The ability to print high-end graphics on lay-flat packaging improves brand awareness and increases marketability compared to rigid and paper packaging. Consumers often notice the most innovative designs and vivid graphics first when shopping.
• Customization: Caltex Plastics has been helping clients create tailor-made packaging solutions for decades. Whether you require resealable closures, tearaway notches or hang holes, our experienced professionals can help you develop the optimal design for your application.
• Eco-friendliness: Because flexible packaging designs like lay-flat pouches are more efficient to manufacture and use less material than traditional designs, they typically use less fossil fuel and water while producing fewer greenhouse gas emissions.

Find Lay-Flat Packaging at Caltex Plastics Today

If you’re looking for a versatile, economical pouch design for your products, a lay-flat bag may be an ideal choice. Our design team can work with you to choose the material, size and manufacturing options best suited to your needs. Connect with us online to get started today.