Roll Films for Sachet and Strip Packaging: Efficiency and Innovation in Flexible Packaging

In the fast-evolving world of packaging, Roll Films for Sachet and Strip packaging have emerged as one of the most versatile and cost-effective solutions. Used widely in the food, pharmaceutical, cosmetic, and personal care industries, these films play a vital role in ensuring product protection, hygiene, branding, and consumer convenience.

This article delves into the intricacies of roll film packaging, the materials involved, how it works, and its relevance across industries.

What Are Roll Films?

Roll Films for Sachet and Strip are flexible packaging materials that come in roll form and are designed to be processed on form-fill-seal (FFS) machines. These machines form the film into a pouch or strip, fill it with the product, and then seal it—usually in a single continuous operation.

Depending on the application, these roll films can be laminated, printed, or coated with barrier layers to enhance performance.

Sachet and Strip Packaging: A Quick Overview

• Sachets are small, sealed, flexible pouches typically used for single-use products. Think of shampoo pouches, sugar sachets, or ketchup packets.
  
  

• Strip packs are similar but often used in the pharmaceutical industry, where tablets or capsules are sealed between two layers of film and cut into single- or multi-dose formats.
  
  

Both packaging formats rely heavily on the right type of roll film to maintain product integrity, shelf life, and user-friendliness.

Common Materials Used in Roll Films

Roll films for sachet and strip packaging are usually made from multi-layer laminates that combine various materials to deliver strength, sealability, and barrier properties. Common materials include:

1. Polyester (PET)

• Excellent printability
  
  

• High strength and dimensional stability
  
  

• Often used as the outer layer
  
  

2. Polyethylene (PE)

• Heat-sealable
  
  

• Moisture-resistant
  
  

• Often used as the inner sealing layer
  
  

3. Aluminum Foil

• Offers excellent barrier against light, moisture, and oxygen
  
  

• Common in pharmaceutical strip packs
  
  

4. BOPP (Biaxially Oriented Polypropylene)

• Good moisture barrier
  
  

• High clarity and strength
  
  

• Common in food sachets
  
  

5. Paper Laminates

• Used in herbal, tea, and dry powder sachets
  
  

• Eco-friendly and biodegradable options
  
  

Types of Roll Film Laminates

Depending on product requirements, manufacturers choose specific laminate structures such as:

• PET / PE
  
  

• PET / ALU / PE
  
  

• BOPP / MET BOPP / PE
  
  

• Paper / ALU / PE
  
  

• PET / MET PET / PE
  
  

Each structure serves a different need—whether it's preventing moisture entry, protecting from light degradation, or enhancing puncture resistance.

Applications Across Industries

1. Food & Beverage

• Ketchup, sauces, sugar, coffee, spices
  
  

• Powdered drink mixes
  
  

• Nutritional supplements
  
  

2. Pharmaceuticals

• Tablet and capsule strip packs
  
  

• Oral rehydration salts (ORS) sachets
  
  

• Topical ointments in single-use sachets
  
  

3. Personal Care & Cosmetics

• Shampoo, conditioner, and lotion samples
  
  

• Wet wipes
  
  

• Face masks and creams
  
  

4. Industrial and Agricultural Products

• Pesticides in powder or gel form
  
  

• Fertilizer concentrates
  
  

• Engine oil sachets
  
  

Advantages of Using Roll Films for Sachet and Strip Packaging

✅ Cost-Effective

• Reduces material wastage
  
  

• Allows for high-speed automated production
  
  

• Requires less packaging material per unit
  
  

✅ Customizable

• Films can be tailored for barrier, thickness, texture, and sealing strength
  
  

• Allows for full-color printing and branding
  
  

✅ Enhanced Shelf Life

• Multi-layer structures provide strong barriers to moisture, oxygen, and UV light
  
  

✅ Portable and User-Friendly

• Sachets and strips are lightweight, single-use, and convenient to carry or distribute
  
  

✅ Hygienic and Tamper-Evident

• Heat-sealed packaging ensures cleanliness and product safety
  
  

Manufacturing and Packaging Process

The typical process for roll film packaging involves:

1. Material Selection – Based on the product's barrier needs and sealing requirements
   
   

2. Lamination – Films are combined to form multi-layer structures
   
   

3. Printing – Custom designs are applied using rotogravure or flexographic printing
   
   

4. Slitting and Rewinding – Rolls are cut into specific widths for FFS machines
   
   

5. Form-Fill-Seal – The film is shaped into sachets or strips, filled, and sealed automatically
   
   

Sustainability and Environmental Challenges

As flexible packaging continues to grow, so do concerns about its environmental impact—especially with multi-layer plastics that are hard to recycle.

🌱 Sustainable Trends in Roll Film Packaging:

• Mono-material films: Easier to recycle than composite laminates
  
  

• Bio-based films: Derived from renewable sources like starch or cellulose
  
  

• Compostable films: Certified to break down under industrial composting conditions
  
  

• Recyclable PE or PP structures: Designed for compatibility with existing recycling streams
  
  

Brands and converters are also investing in lightweighting, solvent-free lamination, and digital printing to reduce carbon footprints.

Industry Trends and Innovations

• High Barrier Films: Advanced coatings (e.g., AlOx, SiOx) offer metal-like barrier properties without the weight or recyclability issues of aluminum foil.
  
  

• Digital Printing: Enables small-batch, high-resolution custom prints for product differentiation.
  
  

• Smart Packaging: Integration of QR codes, anti-counterfeiting features, and sensors.
  
  

• High-Speed FFS Machines: Improve efficiency for sachet and strip pack production.
  
  

Conclusion

Roll films for sachet and strip packaging are essential components of modern packaging systems. Their ability to combine cost-efficiency, customization, and product protection makes them indispensable across various industries. As consumer expectations evolve and sustainability becomes a priority, the flexible packaging industry is poised for innovation.

Whether you're a product manufacturer, a packaging engineer, or a consumer, understanding the role of roll films helps you appreciate the intricate balance between function, cost, design, and environmental responsibility.