Description

1 Introduce

This 3Liter standup spout cap doypack for household detergent is the most appreciated in the consumer market, which is able to provide a strong and nice package for the products. The standing effect of the sachet makes it possible to include the product effectively at the point of sale.  This spout package is very practical for handling and can be produced with a lot of volumes like 500ml 1000ml,  2000ml, 3000ml or even 4000ml or 5000ml.

Our company is a reliable manufacturer of these standing package with spout & closure system for kinds of household detergent. In this post, we are going to share our experience with you about this pouch.

You can understand by watching the video below this 3000ml standup screw cap doypack package for apple juice .

2 Foil Materials

Usually, a mono layer film materials is not feasible to achieve the multiple functions required by this apple juice package 3000ml. The amazing artwork print, robust package , good standing profile will have to need a reinforced 4-layer foil structure, which can be well sealed into a bottom gusseted standup bag. Here, the graphic below shows the common structure intended for this apple juice sachet.

Let’s first get a further understanding on each substrate layer material.

PET12, is one of the most commonly used printing substrates in flexible packaging pouches. With great optical clarity, high gloss, good chemical resistance, stable mechanical strength, excellent dimensional stability, and great printability, it can present the customer artwork print in great quality, and also provide great mechanical strength to the final package.

Al7, is short for aluminum foil metal sheet with a thickness of 7 microns, which is the most commonly used thickness in flexible packaging. It has the best barrier performance among all the film materials, which can keep the original flavor and fragrance for a prolonged time. Aluminum foil is 98.5% aluminum, with the remaining percentage primarily made of iron and silicon to increase strength and puncture resistance. Finally, it is achieved with optical properties, such as durability, non-toxicity, oil-proofness, chemical resistance, and good thermal conductivity.

PA15, means the biaxially orientated polyamide film 15 microns, which is one of the most common used robust films in the commercial market, and works as middle support layer.

LDPE film, which is short for low density polyethylene film, will have to be modified to meet the particular requirements for the inside contents. Here, it mainly works as the inner sealing layer.

The final thickness for this foil laminate should be 120 microns, with a tolerance +-5%. and the toughness will be enough to present a good standing effect for finished bags.

3 Properties and Quality Assurance

3.1 Exquisite print quality

The artwork is achieved in gravure printing on our rotogravure print press which can print up to maximum 10 colors. With advanced print techniques and print defects inspection system, we are now outputing fantastic print effects for the customers’ artwork.

You are advised to watch the video below to have a further understanding of the print quality of this 3L screw cap spout doypack package.

In our manufacturing plant, we take serious measures to achieve high color fidelity and consistency for repeated printed orders, and here we are going to give a basic introduction.

a.  Color Analyzer

This color analyzer is one of the auxiliary tools in our system to achieve the highest standard for color fidelity. The eXact Advanced doesn’t just validate the color of CMYK and spot color inks, it can simultaneously measure four M modes to visualize the spectral reflectance of a substrate or ink, measure the concentration of a specific ink, and measure the difference of a substrate or ink over white and over black.

b. Pantone Color Code

Pantone color guide would be so helpful to locate a specific color for the pring service supplier and the customers, especially there is a large area printed in single Pantone color. For many Pantone colors, the accurateness may be influenced by the printer, paper substrate and environmental factors when it is printed onto physical photo paper. We will locate the Pantone Color Code with the customers in their artwork design before the order is put into produce.

c. Physical Printed On Photo Paper

The computer files such as JPG, PDF, PSD, AI etc can not be taken as the guide to determine the color in print produce, as they present the colors through electronic screening devices. And different electronic screens may be set in different parameters by the various manufacturers, which will inevitably interfere with the colore presentation. Artwork can only be a reliable guide when printed on physical substrate, with the most common photo paper applied.

You may read here to understand more about how our company ensures color fidelity and consistency for all our orders.

Measures taken to achieve high color fidelity and consistency in reprints

3.2 Excellent Glossy Finish Effect

The glossy finish effect of this amazing pet product bag is achieved by printingon  a layer of PET substrate.

You are advised to watch the video below for further understanding.

There are also some other options to achieve the matte finish effect for the bag packages, and here you may this post if you are interested.

How is matte finish achieved on standup pouches

3.3 Excellent Dimension Stability

When packagers want to improve production efficiency with high-speed filling lines, there are increasing requirements for the dimensional stability of bags. We have a good understanding of this and are working hard to close the dimensional tolerances on every order produced in our long-term supply.

3.4 Delicate Bag Making

The bag is achieved with delicate details, which can create a perfect impression for the consumers when they pass by the products, and cause them a purchase. Some customers do like to buy a product out of its gorgeous profile.

3.5 High Barrier Performance

As explained previously, this foil laminate is finalized with a layer of thin aluminum metal sheet, which is of the best barrier performance against oxygen and moisture vapor. Usually, the roasted beans should be well protected to keep the original flavor and fragrance for a prolonged period, to enable the beans enjoyed by the end consumers.

3.6 Fantastic Standup Effect

The bottom of this 3L screw cap spout doypack package is much like a box when the roasted beans are filled, and that will make the package well stand up on the goods shelf, good for branding and sale.

3.7 Great Mechanical Strength

This reinforced laminated foil can greatly protect coffee beans ranging from 100g to 5lb volume.

We perform various inspections and tests to check the mechanical strength of the finished pouch, like drop tests, hard sudden strikes, anti-pressure tests

• Tensile Strength
• Sealing Strength
• Anti-puncture Strength
• Burst Impact Strength
• Anti-pressure Property

The above tests are performed against each order, on customer requirements, and you may check the exact values of this foil material PET12/AL7/PET12/LDPE in the Technical Date Sheet part of this post.

3.8 Easy Filling of apple juice

A large opening can be achieved on the apple juice bag, which enables the easy and fast filling of apple juice into the pouch.

4 Quality Control Measures

Serious quality control measures have been taken in our manufacturing plant, to ensure each order is finished meeting the requirements of particular customers. With more than ten years of working experience in this field, we finalize this QC manual standard, to make sure each order is produced following the correct procedure.

Here, please allow us to guide you further into our QC system.

4.1 Manufacturing Traceback

We apply a strict recording system to document the manufacturing details, such as environmental conditions, craftsmanship parameters, production facility conditions, etc, which allows us to trace back whenever there is a problem.

4.2 QC Test Report Against Each Order

There will be a QC test report issued against each order produced, with the core items evaluated in it.  It is highly appreciated by our customers.

You may read here to understand the QC test report for an order of 250g and 1000g coffee bags.

4.3 Print Inspection

In our manufacturing plant, the print inspection is always taken and done in a serious way, as we will never allow the customer artwork to be achieved in a way that deteriorate their business. On our gravure print press, there is in-line inspection system which can eliminate more than 98% of the defects in the printing process.

You may check how it works on our control panel.

 

There is also a supplementary off-line inspection equipment, to allow us to do the print inspection again whenever it seems necessary.

We are now producing coffee bags against customer artwork, and we surely love to support the startup and market-testing period for our customers. We will accept a minimum order quantity of 10,000 bags printed against customer artwork design.

4.4 Airtight Property Test

The finished coffee bag should be completely airtight, to get the products well-protected from oxygen and moisture in the environment. We perform the airtight property test against each order with the device as below.

In actual operation, we will pick up 1 bag every 1,000 pcs, and perform the test following the procedure in our QC manual.

4.5 Gas Release Property Test

The gas will be released from the inside when the air pressure for the inside is 2~7 mbar than the outside environment. Usually, we will immerse the valve welded bag under the water, and check if the degassing valve works well.

4.6 Drop Test

Drop test should be considered as a very reliable way to check if the apple juice bag strength is enough to meet the various conditions, as it copies the way when the products falls off the good shelves, and the finished bag will suffer great sudden shock. In our daily QC work, We perform drop test against each order, of course, the standard for this drop test should be decided against customer needs.

Here, we are going to drop the filled coffee bag from 1.6m high, for 5 times.

You are advised to watch the video below, for a further understanding.

After 5 drops for each bag, none of them breaks,  all are fine and dandy.

4.7 Hard Sudden Strikes on inflated coffee bags

Hard sudden strikes should be taken as a more fierce test method than drop test, as it causes much higher force on inflated packages.

Let’s watch the video to understand how we perform this test in our manufacturing plant.

4.8 Anti-Pressure Test

Pressure-resistance test is another effective method to decide if the final package will serve as great protection for the products, especially liquid products, like household detergent liquids, and windshield washer fluids. For coffee bags, we will perform the anti-pressure test in our daily QC work, to ensure each order is finished with great mechanical strength.

The leakage or breakage of the coffee bag will surely be a disaster, either for the distributor or the manufacturer.  We will never expect this thing happens in our customer’s business.

Sometimes, for easier and fast operation, we may just get one person to stand on the well-sealed and inflated coffee bag, to check if there is any burst of them.

4.8 Laboratory Tests

Laboratory tests are essential to keep us updated with the intrinsic properties of the foil materials which are not visible to the human eyes. It is crucial for gaining a thorough understanding of the data about the production of our bags. The craftsmanship can be improved bit by bit to pursue premium quality bags based on thorough analysis and application of these data. You may check more of these tests in the Technical Data Sheet part of this post.

4.9 Third-party Inspection

Third-party inspection is available for all our orders on agreed standards or regulations.

5 Human Food Safety

All the film materials, inks, adhesives, and solvents used to convert into kinds of food bags and packaging materials will comply with the regulations for human food safety. The below graphic shows the mass spectra in migration tests on these multilayer flexible pouches these are in direct contact with foods.

Through the below link, you will be able to study the certificates on each of the materials adapted in our factory.

Human Food Safety

6 Package Dimension and Filled Level

Nevertheless, the customer needs to locate a fine dimension for his expected packages, and we will be of the best assistance in locating the fine options for our customers.

For this 3L apple juice bag, we are going to fill 3L of dark roasted coffee beans into the pouch and see the final filled level.

 

Please watch the video below to have a further understanding on the dimension test and filled level.

Here we attach the PDF file showing the package dimension report for this 3L apple juice standup doypack. You may just download and forward it to your customers whenever you need.

Coffee-340g-Flat Bottom-W125xH230+Box Bottom40x2 mm -Package Dimension Test#401

Please note, that the density of apple juice we use is 3000ml, that may vary from the exact density of customer products. We are glad to provide bag samples for customers’ tests.

7 Dieline of 3L apple juice standup doypack

360 250 140

The die-line of this 3L apple juice standup doypack is essential when the customers want to achieve a fantastic artwork design for their package. All the details, like dimension, valve position, zipper position are well stipulated in this die-cut line.

We attach the editable PDF file here, and the customer can just download and forward it to his designer for further creative work.

Design Template 12oz coffee beans W125XH230+Gusset80+Flat Bottom Pouch

8 Technical Data Sheet of 12oz aluminum foil flat bottom coffee bag

Here, we include the specifications on some main items of this multilayer coffee bag, with the videos showing the test progress in the later columns.

You may check attached PDF file for a further knowledge on the specifications of this 12oz aluminum foil coffee bag.

TL-549 Technical Data Sheet of 12oz-LifeBoost-box-bottom-coffee-bag

Some main items are listed below.

1. Dimension Tolerance
2. Print Appearance
3. Yield (grams per square meter)
4. Tensile Strength (Mpa)
5. Elongation Rate  (%)
6. Coefficient of friction, short as COF
7. Solvents Left (mg/m2 )
8. Sealing Strength (N/15mm)
9. Sealing Conditions
10. Bond Strength (N/15mm)
11. Burst Strength (J)
12. Anti-Puncture ability (N)
13. Drop Test Ability (cm)
14. Anti-pressure ability (kgs)
15. Water Vapor Transmission Rate (g/m2/24hr)
16. Oxygen Transmission Rate (cc/m2/24hr)

Just reach us if you have any questions with any of the items.

9 More Sustainable Options

With the increasing burden on plastic pollution, more and more manufacturers are now seeking more sustainable packages, like compostable film materials, recyclable mono materials packages, and plant-based materials packages. They all prove to be more eco-friendly and sustainable than the traditional plastic films which are usually derived from fossil chemicals, and very difficult to recycle and break down in the environment.

Here, we are going to share some of the trending sustainable packages for the coffee market.

9.1 Compostable film material packages

Thanks to the fast development of plant-based film materials, we can present the multi-layer standup pouch and roll foils in full compostable and biodegradable options.

 

The compostable substrate films we adapt to convert the multi-layer flexible pouches are listed below.

1. BOPLA Film
2. PLA+PBAT Film
3. Kraft Paper
4. Metallized Paper
5. Cellulose Film
6. Metallized Cellulose Paper
7. PBS Film
8. PVDC Coated Cellulose Film
9. Metallized BOPLA Membrane

We are now achieving multilayer compostable foil materials based on extrusion coating lamination, solvent-free lamination and dry lamination, and then convert into various types of flexible pouches against customers’ requirements.

Some of the common compostable foil structures are listed below.

• Kraft Paper/PLA+PBAT Membrane
• Kraft Paper/BOPLA Membrane
• Cellulose/PLA+PBAT Membrane
• Kraft Paper/PBS Foil Membrane
• Metallized Paper/PLA+PBAT Membrane
• BOPLA/PLA+PBAT Membrane
• Cellulose/Metallized Cellulose/PLA+PBAT Membrane
• Kraft Paper/Metallized Cellulose/PLA+PBAT Membrane
• Cellulose/Metallized Paper/PLA+PBAT Membrane
• Kraft Paper/Cellulose/PLA+PBAT Membrane
• Kraft Paper/Cellulose/PBS Membrane
• Metallized Paper/Cellulose/PLA+PBAT Membrane

Here, we are going to introduce the main performance of these compostable materials pouches.

a. Compostable

All the film materials we adapt are certificated compostable, under home or industrial conditions, complying with the standards EN 13432 or ASTM 6400.

 

 

 

 

 

 

 

 

 

 

The films will present different biodegradation behaviors under different conditions, such as industrial composting facilities, home and garden conditions, and nature soil conditions.

In most cases, industrial composting will be able to achieve a faster biodegradation of the compostable film materials than other composting progress, as it is able to provide better conditions.

Some manufacturers would like to have a better biodegradation behaviors of their own compostable packages under nature soil conditions, as in most cases, the abandoned package may not be recycled into human composting facilities.

You may read here to have a better understanding of the break-down progress of our compostable foil laminated materials under the nature condition in Qingdao, Shandong, North China conditions.

The biodegrading process of compostable film materials buried in nature soil

b. High-barrier performance pouches

Through vacuum metallization, PVDC coating, and AlOx/SiOx depositing, the compostable films can be achieved with better barrier performance, such as water vapor transmission rate (short as WVTR) and Oxygen Transmission Rate (short as OTR). Later on, we will combine several layers of the barrier film and convert into laminate foil, with an improved barrier property for finished packages.odles, or soup products

In below table, we are going to share some barrier data of the most common foil laminates tested on our Mocon permeation tester.

Biodegradable Foil Laminate	WVTR (g/m2/24hr)	OTR (cc/m2/24hr)
BOPLA40/PLA+PBAT60	62.2	267
Cellulose30/PLA+PBAT60	131.5	5.6
Kraft Paper45g /PLA+PBAT60	44	742
Kraft Paper45g/BOPLA40	41	380
Metallized Paper69g/PLA+PBAT40	27	127
Cellulose30/Metallized Cellulose20/PLA+PBAT60	23	0.16
Cellulose30/Metallized Cellulose20/BOPLA40	25	0.12
Metallized Paper 69g/Cellulose30/PLA+PBAT60	5.6	1.12
Kraft45g/Metallized Cellulose20/PLA+PBAT60	26	0.22
Cellulose30/Kraft45g/PLA+PBAT60	19	117.2
Cellulose30/Metallized Paper69g/PLA+PBAT60	8.9	1.1

c. Alkaline Resistant

We put a certain amount of bleaching powder into the compostable pouches with various foil structures, and place them in an environment of 40~45 Celsius degree, to accelerate the aging process of the compostable pouches.

The test result proves the compostable pouches will be fine for packing alkaline products, like household detergent powder, and hand wash cubes.

However, it is not ok for household liquid detergent and other liquid cleaning chemicals.

You may watch the video below for further knowledge on it.

d. Frozen Treatment

The compostable pouches can be well intended for frozen treatment for some food products, and the mechanical property of the frozen pouch still works well as good protection for the products during the transportation and distribution process.

You may watch the video below to study the test in our office.

d. Vacuum Packages

The compostable pouches can be intended for the vacuum packages for products, like milk powder, nutrition products, etc.

f. Hot Filling up to 100 Celsius Degree

The compostable pouch will be fine for the hot filling process, which may work well for juice products.

Watch the video below to learn our test.

g. Microwave Oven Treatment

The compostable doypack can be well intended for microwave oven treatment, such as melting the candle wax, etc.

Please note, there should not be metalized film layer in the compostable pouch when it is intended for this microwave treatment purpose.

You may read here for better understanding on the compostable plant-based film materials packaging.

Compostable Plant-film Materials Pouch Packaging

9.2 Mono Materials Recyclable Pouch Packages

Mono meterials pouch packages are truly recyclable, as they can be easily processed into plastic granules which can be used again for other applications. However, for the traditional multilayer laminates, take PET/LDPE for example, it is difficult to process, as PET and LDPE are quite different materials, and can not be melted under the same conditions. That’s why momo materials pouch packages are becoming so widely popular in the packaging field, and highly reputed in the consumer market.

At present, mono-materials pouches are divided into Polyethylene channels and Polypropylene channels, with polyethylene channels much more popular, as they can be converted into kinds of standup pouch packages with relatively high performance.

Here we list the film materials that can be well intended for mono-materials recyclable pouch packages.

1. MDOPE Film
2. BOPE Film
3. APE Film
4. LDPE Film
5. LLDPE Film
6. CPE Film
7. ABOPP Film
8. CPP Film
9. VMCPP Film
10. VMBOPP Film
11. EVOH-LDPE Film
12. HDPE Film

Various foil laminates can be achieved based on the above film materials with different properties, which are intended to meet the particular requirements for specific products. Some of the common mono-material foil laminates are listed below.

1. MDOPE/APE
2. MDOPE/LDPE
3. MDOPE/EVOH-LDPE
4. MDOPE/HDPE/APE
5. MDOPE/BOPE/APE
6. BOPE/APE
7. BOPP/CPP
8. BOPP/VMCPP
9. ABOPP/VMCPP

From our experience, mono-materials pouches can be well intended for spices powder products.

You may have a further understanding of the recyclable mono materials and pouches here, and just reach us if you have any questions

Fully Recyclable Mono Materials Package

10 Reliable filling machinery to fill products into this standup bag

Our bags are produced for running on the high-speed filling lines, which maximize the production efficiency for the coffee roasters. Of course, you will have to find a reliable filling machinery to do this job.

Here, we will share with you a reliable filling line to carry on the work of filling beans into flat bottom coffee bags.

Enjoy!

11 About the manufacturer

Qingdao Tongli Packaging has devoted itself to the manufacture of quality coffee bags for more than 10 years, with long-term customers around the world. You may just rely on us if you would like to get a sustainable and reliable supply for your coffee packages.