It all comes down to the right packaging. What is often perceived as an allusion to appearance is also interesting in terms of material selection - and it depends on what shape the packaging is. A very practical question. Cartons are treated differently than bags in everyday life. Flats and Stand-up pouch are in use everywhere today.

According to IK - Industrievereinigung Kunststoffverpackungen e.V., production of packaging films amounted to 1.705 million tons in 2021 alone. A considerable amount, to which packaging made from natural raw materials must be added. When are stand-up or Flat pouch used as packaging? We show you the differences and the possible uses.

What is a Stand-up pouch?

Until a few years ago, classic Flat pouch played the leading role as packaging. Especially in the food trade, Stand-up pouch are now very widespread. Compared to Flat pouch , they have a very concise feature. The bottom is made in such a way that the bags can be presented standing up. This results in various advantages for:

• Manufacturer
• Trade
• Consumer

An obvious plus point is the clearly better presentation of the goods at the point of sale (POS). Stand-up pouch are used today primarily in the food retail sector. In the meantime, however, other sectors - such as pet food manufacturers - are discovering the advantages of this packaging variant. Even the cosmetics industry is increasingly relying on Stand-up pouch.

Differences in shape and choice of materials

Stand-up pouch, also known as doypacks, come in a variety of shapes and material choices. One of the differences that you do not immediately notice is the shape of the bottom fold.

This can be incorporated into the doypack as a doyen bottom, as a plow bottom type or in the form of a so-called K-seal bottom. On the one hand, the shapes of the stand-up pouch differ in the effort required for their production. On the other hand, the different bottom types are adapted to different applications.

• Doyen bottom: Can build up very much in volume and is therefore ideal as packaging that stands by its own weight of the package contents. Used this type of packaging generally for rather small weight units.
• K-Seal bottom: This variant is used for larger weight units. Due to the shape of the bottom gussets, the Stand-up pouch does not expand as much and the package contents tend to be distributed over the height of the bag. These Doypacks are used for granules or ground products, such as spices or food supplement powders.
• Plow Bottom: The Plow Bottom stand-up pouch is similar to the K-Seal bottom in the shape of the bottom fold, but can hold significantly more volume. This form of doypack is suitable for large weight units of several kilograms - for dog and cat food, for example.

As far as the choice of materials is concerned, many Doypacks are still made of plastics. This naturally results in certain advantages, for example in terms of food safety. The contents remain very well protected against external influences - be it light or moisture. As far as sustainability is concerned, this material decision is not optimal.

Manufacturers are therefore now also offering other material solutions. There is demand for paper-based stand-up packaging. Two different approaches have become established here.

1. Kraft paper + polyethylene (PE)/ethylene vinyl alcohol copolymer (EVOH): This is a combination of different materials. On the outside, tear-resistant kraft paper is used to make the Doypack, giving the packaging a natural look. On the inside, plastics or ethylene vinyl alcohol copolymer are used, creating a very secure barrier.
2. Mono paper: So-called mono paper doypacks are made of 100 percent paper. The kraft paper already mentioned is often used for the outside. White paper grades can be found on the inside. Such Doypacks have the advantage of a very high sustainability factor, but are not suitable for all products. Liquids and liquid oils and fats are not suitable for mono-paper stand-up packaging.

To avoid as much plastic as possible, two more sustainable alternatives have become established: Kraft paper with a PE/EVOH coating on the inside and Doypacks made of mono-paper.

What is a Flat pouch?

Flat pouch are classic packages that you know from the supermarket shelves. For example, dairy products such as cheese spread or confectionery are packaged in this way. Plastics are still used to a very large extent in their manufacture. Tubular films are used for this purpose, which can be processed into packaging with very different filling volumes.

Flat pouch are usually presented lying or hanging in corresponding displays. For some packaging sizes and contents, upright presentation in corresponding outer packaging units/displays made of cardboard is also possible.

With regard to the choice of materials, especially in the food sector, manufacturers focus on plastics to ensure a high level of flavor safety and leakage protection. For some applications, kraft papers are also used. However, very similar restrictions apply here as for Doypacks.

Basic advantages and disadvantages of the variants

Flat pouch are classic packaging and are familiar to many consumers in this form. Depending on the presentation, Flat pouch can be used horizontally or suspended at the POS. As far as the advantages and disadvantages of Stand-up pouch and Flat pouch are concerned, there are overlaps.

Common advantages of both forms of packaging

In practical use, floor-standing and Flat pouch havecommon advantages due to the choice of materials, among other things.

• Doypacks as well as Flat pouch are perfect when it comes to a storage of perishable food. The use of plastic or a combination material of plastic/EVOH and paper creates a barrier to the outside. Substances can neither get into the packaging nor out of the packaging to the outside.
• Both packages can protect the contents from ultraviolet radiation. The latter can influence the quality of the contents. With the right choice of material, both variants are on a par. In addition, the packaging also protects the contents from oxygen.
• Flat pouch as well as Doypacks are very light and thus save weight. In addition, transport is much easier than, for example, glass. Here, transport is additionally challenging due to the high risk of breakage. Doypacks and Flat pouch are much more resistant to pressure, do not lose their properties when exposed to moisture and are the better choice in terms of transport costs.
• Both packages can be resealed via a zip closure. This allows the contents to be used for a longer period of time.

Common disadvantages of both forms of packaging

There are not only some similarities in the advantages. There are also overlaps in terms of disadvantages. One very important aspect is the amount of packaging waste. According to the German Federal Statistical Office, packaging waste amounting to 78 kg was generated per capita in Germany in 2020.

A considerable amount, to which, unfortunately, Doypacks and Flat pouch have also contributed. Both types of packaging are becoming a problem because many applications rely on plastics or composite materials with plastics. In the context of recycling, this is definitely a detriment. The sustainability aspect is indeed a major drawback that is evident in both forms of packaging.

Advantages and disadvantages of doypacks

If we are talking only about the advantages and disadvantages of Stand-up pouch, they have several advantages over flat bags. The latter are often made from tubular films. This means that they offer aroma and oxygen protection. Doypacks generally perform better in terms of UV protection.

A second plus point is presentation. Doypacks not only have the advantage of being positioned standing up at the POS. The possibility of using different motifs and materials for the outside means that Stand-up pouch catches the consumer's eye more quickly. In addition, the stand-up base has the advantage that a resealable bag can be stored much more securely.

Advantages of doypacks:

• Presentation
• UV protection
• safe storage
• Robustness

In addition, the use of materials - since larger filling quantities in particular can be realized - is sometimes more favorable in relation to the packaging quantity.

The disadvantages include more complex production, which makes Doypacks more expensive. In parallel, of course, the bottom needs more material than compared to the simple tubular films of Flat pouch. In addition, the use of composite material in recycling is a problem.

Advantages and disadvantages of the Flat pouch

Flat pouch are very easy to manufacture, very robust overall and easy to transport. Foodstuffs in particular can be packaged very easily in this way and transported to the POS or to the consumer.

Due to the small dimensions, the shelf life here - from the

From the point of view of space consumption - very good. In parallel, Flat pouch performs excellently in terms of aroma protection.

As for the disadvantages: The use of transparent tubular films is not always optimal. This is especially true for content with a certain UV sensitivity. Of course, the limitations in presentation are a second important disadvantage.

For which products are the options suitable?

In terms of usability, there are certain overlaps between Doypacks and Flat pouch . In connection with free-flowing products or powders, packaging can take place in both packaging categories.

Spices can be stored in both flat bags and stand-up pouches. The decisive factor with regard to use is not only the type of packaging, but to a considerable extent also the choice of material.

Doypacks are used in practice, among other things, for

• Spices and spice mixtures
• Powder
• Granules
• Nuts / nut mixtures
• Sauces
• Fruit mixtures
• Liquids
• Dairy and milk products
• Food containing oil and fat
• Ready meals

used. An extremely Width range, which in recent years has also been joined by various products from the pet food segment. Many of these products can also be packaged in flat pouches. But: in this case, the packaging quantities are not as freely scalable. This restriction rules out the use for certain non-food articles.

Are there differences in terms of sustainability and price?

Basically, the price always depends on the size and especially for doypacks on the exact design. Due to the somewhat more complicated production, these are more expensive than Flat pouch.

The magnitude of this difference also depends on the material. In the end, however, you as a consumer usually pay a bit more for a doyback.

This is also where the sustainability aspect is decided. Both types of packaging can be made from monopapers and plastics or composite materials. This decision ultimately influences sustainability.

Conclusion: choose packaging according to the content

Doypacks are appearing everywhere in POS today in parallel with Flat pouch . These are not necessarily the better alternative in packaging. In some areas they are more practical and present the contents differently. However, Flat pouch , which is based on a tubular film, can convince in terms of price - and thus has its justification in any case. In the end, the content decides which packaging is used for your product.