Flexible Packaging 101: A Guide to Rollstock Packaging

Rollstock packaging has quietly become the backbone of modern manufacturing, powering everything from your favourite snacks to pet food pouches. If you're wondering whether rollstock is right for your business or looking to optimize your current packaging process, this guide breaks down everything you need to know in simple terms.

What Is Rollstock Packaging?

Think of rollstock as packaging that gets made while you watch. Instead of buying pre-made bags, rollstock uses continuous rolls of flexible film that feed into form-fill-seal (FFS) machines. These machines work like magic—they unwind the film, shape it into pouches, fill them with your product, seal them shut, and cut them apart, all in one smooth operation. The beauty lies in its simplicity. Your packaging line becomes a well-oiled machine that can produce hundreds of packages per minute without missing a beat.

How Rollstock Works

The process follows four straightforward steps:

1. Film Unwinding: Large rolls of specialized film feed into your FFS machine, ready for transformation.
2. Forming: The machine shapes flat film into whatever style you need—pillow bags, stand-up pouches, or gusseted designs.
3. Filling: Your product gets precisely dosed into each freshly formed pouch.
4. Sealing & Cutting: Heat seals create secure closures while cutting mechanisms separate individual packages from the continuous roll.

This automated approach eliminates bottlenecks and keeps your production line humming along efficiently.

Why Rollstock Makes Business Sense

Operational Efficiency That Pays Off

Rollstock's biggest advantage is speed. While manual packaging processes struggle to keep up, rollstock-powered lines can package products at rates that would be impossible otherwise. You'll need fewer people on the line, make fewer mistakes, and maintain consistent quality across every package. The continuous nature of rollstock also means fewer changeovers and less downtime—your equipment keeps running while your costs stay low.

Real Cost Savings

Multiple factors make rollstock a smart financial choice:

• Lower material costs: Rollstock film typically costs less per unit than pre-made bags, especially for larger production runs
• Minimal waste: You use exactly what you need for each package, eliminating excess trim
• Reduced storage expenses: Compact rolls take up far less warehouse space than bulky pre-made packaging
• Lower labor costs: Automated processes reduce staffing needs while boosting output

Flexibility That Grows With Your Business

Need to switch between different package sizes? Change your branding graphics? Adjust for seasonal products? Rollstock handles it all with quick, simple changeovers on your FFS machines. High-quality printing capabilities ensure your branding looks sharp and professional, helping your products stand out on crowded shelves.

Specialized Features That Make a Difference

Modern rollstock solutions include smart features that solve specific packaging challenges:

Air Evacuation Solutions

• Air slits provide cost-effective perforations that let air escape quickly during packaging, keeping your production lines running at full speed while maintaining product freshness.
• Micro-perfs hide in bag gussets to release air without affecting the package's appearance—perfect when aesthetics matter.
• Needle perfs offer smaller, less visible punctures ideal for finely ground products like spices, providing controlled air evacuation without compromising product integrity.

High-Performance Film Options

• Surface print offers an economical way to showcase bold graphics on recyclable mono-material films that work seamlessly with your existing equipment.
• Reverse print protects your branding from wear and tear by placing graphics inside the packaging, visible through clear film layers.
• Microwaveable films withstand high heat without distorting, with precise venting already built in for consumer convenience.
• Boil-in-bag options handle extreme temperatures from freezing to boiling without affecting product quality.

Where Rollstock Excels

Food and Beverage Industry

Rollstock shines in food packaging thanks to superior barrier properties that maintain freshness. Whether you're packaging snacks, coffee, frozen foods, or liquid products, rollstock films provide the protection your products need while meeting strict food safety standards.

Pet Food Manufacturing

Pet food brands benefit from rollstock's durability and customization options. These films handle everything from kibble to wet food while maintaining nutritional value and preventing contamination.

Personal Care and Beyond

From wipes to cosmetics to cleaning supplies, rollstock creates user-friendly packaging with custom shapes and eye-catching graphics that capture consumer attention.

Sustainability That Makes Sense

Built-in Efficiency

Rollstock naturally reduces waste through continuous film rolls and minimal trim requirements. This efficiency translates to lower material usage and reduced shipping costs—unformed rolls are much more compact to transport and store.

Eco-Friendly Options

Modern rollstock embraces sustainability through:

• Recyclable mono-material films that simplify the recycling process for consumers while maintaining performance.
• Post-consumer recycled (PCR) content that incorporates recycled materials, reducing environmental impact without sacrificing quality.
• Bio-based films that use renewable materials, helping reduce dependence on fossil fuels.

Lightweighting Innovation

Advanced film technology enables thinner materials without sacrificing strength or barrier properties. This approach reduces plastic usage per package while maintaining excellent product protection.

How to Choose the Right Rollstock Solution

Start With Your Product Needs

Different products require different film properties. Sensitive foods might need specialized barrier films, while liquid products require strong seal integrity. Powdered products might benefit from anti-static properties, and frozen items need temperature-resistant materials.

Consider Your Volume

Rollstock works well for various production volumes, but it truly shines as volumes scale. The high-speed capabilities make it particularly cost-effective for large runs, though smaller batches can still benefit from its flexibility.

Think About Compliance

Make sure your chosen films meet industry standards, especially for regulated sectors like food and medical applications. Working with suppliers who understand regulatory requirements saves headaches down the road.

Partner Expertise Matters

The right supplier can guide you through film selection, graphic design, regulatory compliance, and machine compatibility decisions that maximize rollstock's benefits for your specific situation.

Why Partner With Emmerson Packaging

Emmerson Packaging brings you the expertise and innovative materials needed to make rollstock packaging work seamlessly for your business. Our team helps you choose the right films, meet safety and sustainability standards, and create packaging that stands out—while keeping things efficient and reliable. With our in-house manufacturing, FDA approvals, and a range of eco-friendly options, you can trust us to deliver quality results on time. Let Emmerson Packaging help you make your next packaging project a success.