Why Brands Should Use Refill Pouches in their March Towards Sustainable Packaging

Premade spouted pouches may be a logical solution for many firms. They provide several sustainability benefits, are cost-effective to enter, generate less product scrap waste, and have more pouch options accessible.

Spouted pouches are created by flexible packaging experts who are able to assist businesses throughout the whole process from concept to commercialization. New materials and pouching technology are being developed every other day.

Advantages of Using Refillable Spouted Pouches

Spouted refillable pouches are suitable for eCommerce. Especially with right-sizing pouches, companies need to spec out their packaging to use the exact amount of material optimized for the amount of product they offer.

To minimize product loss and returns, the pouches are tested and built to withstand the rigors of the shipping requirements of eCommerce. They also have a modern look that goes well with design-forward graphic treatments for both on-shelf and online promotions.

Unlike rigid plastic bottles, refillable pouches use less plastic and have the option of using post-consumer recycled (PCR) material. It, therefore, significantly reduces plastic use, creates an additional stream for recycled plastic, and establishes the functionality of the circular economy.

Due to the refill spouted pouch’s reduced weight, greenhouse gas emissions and fossil fuel use are decreased. 

The refillable spouted pouch revolution is being spearheaded by companies such as Kiehl’s, Oribe, Harry’s, Ouai, and Puracy. Each of these has a refill spouted pouch product that supports their goal of creating sustainable packaging.

It enables them to communicate with customers through a novel packaging design and bolsters eCommerce sales.

Below are some of the things done to ensure quality and consistency.

●      Puncture resistance test.

This test determines the amount of pressure the flexible packaging material can withstand.

●      Product/package compatibility test.

It examines how the constituents of the product interact with various packaging materials.

●      Seal testing.

This test is for finding molecular-level fusion seals, which are the same kind of bonds that hold the polymers in a rigid container together when they are produced.

●      Vacuum testing.

The pouches are subjected to the equivalent of 1 atmosphere of vacuum pressure to confirm hermetic sealing.

●      Pouch designing, scaling, and prototyping.

The packaging manufacturer determines the size and configurations of the pouch depending on the product type and volume, and brand image.

●      Drop test.

The pouch is dropped from different heights to determine how far people can drop it without failing.

●      Compression test.

This test involves adjusting the amount of air pressure applied to the pouches for various periods. 

●      Burst test.

This test involves applying pressure on pouches until they rupture to assess the effectiveness of the seals.

●      Tensile testing.

It involves attaching the packaging film to itself and determining how much force is needed to break the seal.

With the help of these quality control components, companies may adapt their refill pouches to different demands, including customer demands, filling machine and copacker specifications, distribution strategies, intended shelf life, and legal requirements.


Refill pouches will become increasingly popular when recycling infrastructure is updated to handle a wider variety of flexible packaging. Refill spouted pouches’ recyclable forms are also constantly being expanded to allow PCR or shop drop-off recycling.

Municipalities and all flexible packaging sector partners must increase their investments in recycling infrastructure if we are to keep improving our system. The momentum of the refill spouted pouch will act as the driving force as businesses continue to increase the accessibility of these pouches.

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