What Is Rollstock?
Rollstock is a continuous roll of flexible packaging material used in form-fill-seal (FFS) machines to create pouches and bags efficiently. Unlike pre-made pouches, rollstock allows manufacturers to form, fill, and seal packaging in one process, making it faster and more cost-effective. It also supports customization, meaning brands can incorporate features like zippers, resealable closures, and high-barrier films to enhance product protection and user convenience.
How Rollstock Packaging Works
In rollstock packaging, a continuous roll of film is fed into an FFS machine, where it is shaped into a pouch, filled with product, sealed shut, and cut from the roll in one streamlined process. This high-speed automation significantly reduces material waste and increases efficiency compared to using pre-made pouches.
Machine Types & Pouch Styles
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Vertical Form-Fill-Seal (VFFS) – Creates pillow pouches, gusseted bags, and stick packs.
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Horizontal Form-Fill-Seal (HFFS) – Produces stand-up pouches, 3-side seal pouches, and flat pouches.
Industries That Benefit from Rollstock Packaging
Rollstock is widely used in industries requiring high-speed, high-volume packaging, including:
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Food & Beverage – Snack pouches, coffee bags, protein powders.
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Pharmaceuticals & Medical – Single-dose medications, medical device packaging.
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Pet Food – Dry food pouches, treat bags.
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Cosmetics & Personal Care – Face masks, sample sachets.
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Cannabis & Nutraceuticals – Child-resistant packaging for edibles and supplements.
How Much Volume Justifies Rollstock?
For businesses packaging at least 50,000 to 100,000 units per month, rollstock packaging offers substantial savings in material costs and labor efficiency. Companies handling hundreds of thousands to millions of pouches per month can achieve even greater benefits from this automation.
Working with a Third-Party Packager (3PL)?
If you rely on a third-party logistics (3PL) company or contract manufacturer for packaging, the first step is to identify the equipment they use. Since rollstock packaging machines have specific design and sealing requirements, your packaging must be tailored to their machine capabilities to ensure proper fit, seal strength, and overall performance.
Why Use Rollstock?
✔ Lower Costs – Uses less material than pre-made pouches, reducing per-unit costs.
✔ High-Speed Production – Ideal for large-scale manufacturing.
✔ Customization – Works with zippers, spouts, and resealable features.
✔ Better Product Protection – Compatible with high-barrier materials for food and pharma industries.
Is Rollstock Right for Your Business?
If your company requires cost-effective, high-speed, and customizable packaging, rollstock-based FFS systems could be the perfect solution. With the right machine and sealing method, you can increase efficiency, improve product protection, and reduce material waste while scaling production.
Would you like recommendations on rollstock materials for your application? Let’s discuss!