New to Flexible Packaging? Here's Exactly How to Get Started.

Taking the first step towards custom packaging is a major milestone for your brand.At Ainox Pack, we ensure every order goes through a clear and  step-by-step process designed to save you time and give you the premium result. 

Quick Summary: How to Order Custom Packaging

1. Choose your pouch format (Stand-Up, 3-side seal, gusset pouch and etc).
2. Measure your product for the perfect fit.
3. Select the right material and thickness for your packaging.
4. Prepare your print-ready artwork. (In Adobe Illustrator (AI) file, must be CMYK file instead of RGB file)
5. Approve the design for clean-room production and delivery

Let's walk you through together.

Step 1 : Choose The Right Packaging for Your Product

The foundation of great packaging is balancing product protection with customer convenience. You first need to determine the structural format that best fits your product's display needs:

• Stand-Up Pouches: Highly versatile, self-supporting and perfect for retail shelves. (For example: Stand Up Pouch, 8-side seal)
• Flat Pouches (Lay-Flat): Sleek and cost-effective, ideal for single-serve items or sample packs. (For example: 3-side seal, center seal, pillow bag)
• Side-Gusset Bags: Expandable capacity, making them the industry standard for coffee, Milo pack (4-side seal, center seal with gusset poouch)

**Pro Tip: Always think of how your customers will be using the product. Does your snacks or pet food need a resealable zipper to keep freshness? Does your roasted coffee need a one-way air valve to let your customer smell it? 

Step 2 : Measure your product and choose the right size

Achieving the correct dimensions are crucial, as packaging that is too tight can compromise the seal or fail to protect the products. To ensure a perfect fit, we recommend measuring your product’s physical dimensions and total fill weight before requesting the packaging design template. Once you share these details, our packaging specialists will provide expert guidance on the most suitable packaging size, taking into account how your items are filled, sealed and ultimately displayed on the shelf. 

Step 3 :  Select Your Material & Thickness 

Selecting the right substrate directly impacts your product's shelf life, barrier protection and visual appeal.

Material Options:

1. Aluminium (Alu) : The ultimate high-performance barrier against moisture, light, and oxygen. Ideal for highly sensitive items like chips, dried foods and premium snacks.
2. Metallised (VMPET) : It’s actually coating with a thin layer of aluminium. VMPET is an excellent balance of performance and aesthetics. It offers a solid protective barrier and a premium metallic finish at a highly accessible price point, making it perfect for coffee and everyday consumer goods.
3. Nylon (PA) : Known for exceptional puncture resistance and flexibility. This is the top recommendation for heavy, sharp-edged or vacuum-sealed products that endure significant pressure. 

Gauge and Thickness:

Thickness is dictated by product weight and the rigors of the supply chain. Heavier items naturally require thicker, more robust multi-layer structures to prevent tearing. Products shipped over long distances or handled frequently require a higher gauge to maintain structural integrity.
Example as below:

Scenario: 250g of cookies in Stand Up Pouch
Recommended Material by Ainox: Aluminium (Alu) or Metallised (VMPET)
Recommended Thickness by Ainox: 100-110 microns (Reason: The contents is less than 1kg. If the contents are more than 1kg, we will always advice to have at least 120 microns)

**Tips: You don’t need to memorise all the materials specs and function because Ainox Pack team is always available to engineer the perfect custom material structure for your specific products.

Step 4 : Artwork preparation and design

Now comes the creative phase which is bringing your packaging to life visually. Once your size and format are confirmed, a tailored packaging dieline template will be provided to serve as a precise guide for your design.  

For the highest quality results, artwork must be integrated into the template using Adobe Illustrator (AI format). You have the flexibility to manage this process in the way that suits you best. 

• Have your own designer? Simply pass our technical specifications to them.
• Need design help? Ainox Pack’s in-house design team can translate your vision into a professional, print-ready layout.

To ensure a smooth transition to print, it is important to include all essential elements such as the product name, ingredients, weight, contact details and any certifications on the packaging..

Step 5 : Artwork confirmation, Production and delivery

The final step is a smooth and straightforward process designed to get your packaging delivered directly to your doorstep. Once your design is submitted, Ainox team conducts a thorough review to confirm it is 100% print-ready, flagging any potential issues early to ensure the final result meets your expectations.

With the details finalized, production begins in a certified clean room facility of Ainox Pack in Malaysia, where your order is carefully manufactured to maintain the highest food-safe hygiene standards. Once quality control is complete, your finished packaging is shipped straight to you, allowing you to focus entirely on filling your product and preparing for a successful launch.