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Pouches & Flexible Packaging

How it works

Flexible Packaging provides a sustainable alternative to rigid containers. A truckload of flexible equates to 35 truckloads of rigid; an important incentive to reduce transport, real-estate & logistic waste. Karlville offers a vertical approach to the supply of machinery for flexible packaging companies looking to expand their offerings into pouch. Pouch is a complex business as multiple material structures and unique converting challenges add barrier to entrance. Furthermore, unlike labels, flexible packaging has direct food contact, thus requiring converters to comply with important safety regulations & compliance.

In terms of converting, Karlville offers a complete line of machines starting from primary slitting to extrusion coating & lamination as well as post print lamination, inspection, slitting and pouch making. In term of packaging, Karlville continues the vertical machinery integration with spout applicators as well as fillers for food and non-food products. Within the pouch machinery supply, Karlville offers both Thermal & Ultrasonic spout inserting and pouch making solutions with an industry enabling Spouted Pouch Pilot Facility in Miami Florida to support & develop the business. It is important to note that our business strategy is to reduce waste and efficiency from the flexible packaging business by providing turn key solutions for pouches all based from pre-made technology.

Unprinted Film Rolls


Karlville partners with global suppliers to develop pouch applications;
Taghleef Industries





Roto, Flexo, Digital & Offset

As an HP Converting Partner; Karlville partners with HP to develop Flexible Packaging applications for pouches.


In order to save lamination material, increase slitter & pouching efficiency and control your quality process, all print defects must be doctored prior to lamination.


Scoring and perforation LASX equipment integrated to slitter or inspection machines


Solventless, Water & Solvent Based

Karlville provides a multiple range of laminators and extrusion coaters & laminators.


Turret and Duplex slitters, standard or configurable


Scoring and perforation LASX equipment integrated to slitter or inspection machines

Pouch Converting

Thermal & Ultrasonic Pouch Making Capabilities.

With more than 20 years in pouch market, Karlville provides machines to convert pouches with both Thermal and Ultrasonic technologies. See first hand in Miami at Spouted Pouch Pilot facility.

Spout Inserting

Thermal & Ultrasonic spout inserting for railed spouts. Insert on corner or top for Standup, Three Side Seal and Side Gusset Pouches.
View Machinery

Spout Inserting, Fill & Cap

Pouch Filling from premade pouch blanks. Lean supply chain, most cost effective for large volumes. Visit Machinery

From simple lab equipment and market introduction spout inserters to 200 spout per minute applicators, Karlville provides a complete line of solutions for spout for the converter and brand.

Visit Machinery

For higher volume and supply chain ease, spout inserting and welding integrated to the filler.

Pouch Fill & Cap

Fill through spout technology with pre-spouted railed pouches. View Machinery

For smaller volume as well as for simple production ease, filling and capping is an easy way to fill spouted pouches.

Finished product


FPA Publishes E-commerce
Streamlined LCA Case Studies


FPA's Sustainability Life Cycle and Economic Impacts of Flexible Packaging in E-commerce Report provides a holistic view of the sustainability benefits that flexible packaging offers in e-commerce and quantifies the environmental and economic shipping impacts by comparing flexible packaging to other formats across a range of products.

For the report, FPA partnered with PTIS, LLC, and five different LCA case studies were developed using the EcoImpact-COMPASS® LCA software, which allows for quick life cycle comparisons between different package formats:

All primary, secondary, and tertiary packaging, including dunnage from the packages, were used for the assessment. Dunnage is a filler that is used to prevent a product from shifting during shipping, resulting in product damage. Dunnage may be either paper or plastic based, and includes crumpled paper, corrugated inserts, air pillows, and bubble wrap. A dimensional weight and economics comparison for e-commerce was also developed to highlight that the flexible packaging formats demonstrated clear and distinct advantages in reducing the dimensional weight across the product categories.

Additionally, the product-to-package ratio, as well as the amount of packaging that is landfilled for 1,000 kg of each product, was determined. The amount of packaging landfilled was based on the recycling rates for each material while assuming none of the flexible packages were recycled. However, most flexible packaging used in e-commerce applications, including bubble dunnage or poly mailers, are made of LDPE, which can be recycled with grocery bags and other films as part of the store drop-off program. These materials can qualify for the How2Recycle® store drop-off designation if they go through the certification process.

The results from many of the case studies show that flexible packaging has more preferable environmental attributes for carbon impact, fossil fuel usage, water usage, as well as material disposed of when compared to other package formats. This is due to the efficient use of resources enabled by flexible packaging.

E-commerce is a growing economic segment and as more products are shipped via e-commerce, brands continue to look for ways to optimize the shipping, reduce costs, and reduce environmental impact, while offering consumers a positive experience and protecting the product. To achieve these goals, more brands and e-commerce providers are using flexible packaging as either the primary package due to its ability to withstand robust handling and limit leaks or as the e-commerce delivery pack itself as a way to reduce the amount of packaging material and space utilized.

An additional benefit of flexible packaging includes the robust nature of the material, which can help reduce leaks or package breaks, thus significantly improving consumer enjoyment of a product (and brand). This is important in an e-commerce environment where a product is handled at least three times as often as is done within a traditional retail channel.


Kind regards,

Flexible Packaging Association

To follow vertical flexible packaging product line offering:
Lamination »
Slitting & Inspection »
Pouch Making »
Pouch Filling »

Tape Multipacks Solution »
Shrink Sleeves Solution »
Flexible Packaging Videos
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