We spoke to one company that has been innovating in this space, the UK-based digital pouch production specialists Bakpac, which is part of label producer business Bakers.
According to Bakpac, it has recently “hit a major milestone” and is now shipping over one million digitally printed stand-up pouches in a single week.
It noted that “this kind of short-run agility at scale is becoming more appealing to cosmetics brands – particularly startups.”
Global demand for flexible packaging is rising
Indeed, consumer demand for flexible packaging is expected to surge in the cosmetics industry over the next decade.
The global demand for flexible plastic pouches is predicted to grow by 4.5% to a market value of $306.72 bn by 2034 – according to a new report from packaging consulting firm Towards Packaging. Much of this is expected to be driven by significant growth in the North America market.
Specifically in the cosmetics industry, the prevalence of e-commerce and D2C brands are boosting demand for packaging that is cost-effective, lightweight yet durable, recyclable, and able to offer short-run agility at scale.
Key factors influencing market growth for pouch packaging include the rising consumer demand for refillable packs, the use of AI for more efficient packaging, stricter regulations on waste management, and rules and demands surrounding use of certain chemicals, fertilisers and adhesives in manufacturing.
Digital printing itself removes the need for traditional printing plates, allowing businesses to print high-quality designs directly onto packaging materials. In turn, this allows beauty brands to quickly react to market trends while offering smaller and therefore more cost-effective print runs.
Mono-materials are increasingly sought after
BakPac’s parent company, the independent UK label and flexible packaging manufacturer Bakers, said that it significantly expanded BakPac’s production capabilities in May by installing two new Galaxy Packtech pouchmaker machines at its facility in Brentwood, Essex.
Bakers also said these installations will enhance mono-material performance, enabling fully recyclable pouches without compromising on shelf appeal.
The company added that the new pouchmakers offer enhanced sealing technology, specifically designed to improve performance with mono-materials, which are increasingly sought after by beauty and personal care brands for their recyclability.
The company said that the investment also aligns with its “existing digital print firepower,” which includes two HP Indigo 200K digital presses — making it the only UK site to operate this configuration.
It noted noted that beauty brands are now “demanding faster turnarounds, lower MOQs and greater flexibility.”
“Start-up brands can compete with top brands”
Managing director of BakPac and Bakers, Steve Baker, explained that there has been an explosion of companies choosing to use BakPac.
“Start-up brands can now compete with top brands on the quality of their packaging and established brands can now run multi variant products for promotions, regional variations, competitions offers etc. with fast turn round and no compromise on quality,” he explained.
The benefits of these include: “cost per variant, for example, no origination fees, plates, set ups et cetra, as well as speed, as they take seven to 14 days to produce instead of six–eight weeks," he said.
Baker added that easy storage and the ability to order what you want, when you want, with a very flexible supply chain, and UK-based production are all factors making the offer more attractive to beauty companies.
“Very high-quality photographic images can be achieved on the packaging, as well as metallic colours, such as rose golds,” he explained.
“We had a sharp learning curve but quickly realised this is not an area that you can stay small and grow slowly if you want to be successful – our customers are fast moving, fast developing and volumes can increase rapidly," said Baker. “The future is very exciting…”
