Start with the product form
Baby food reaches the shelf in several formats: purees in spouted pouches, dry cereals and formula in stand up pouches or side gusset bags, and snack pieces in flat or three-side-seal packs. The format decides the filling line, the closure and the barrier target. A spouted pouch needs a fitment that survives pasteurisation or hot fill. A dry powder needs a wide fill opening and a reliable zipper.
Map the whole journey before choosing a structure. Will the pack be retort processed, hot filled, or filled at ambient temperature? Is it sold chilled, frozen or shelf stable? Each answer narrows the material list. Getting this wrong is the most common and most expensive mistake in flexible packaging projects.
Barrier is a specification, not a slogan
Barrier means resistance to oxygen, moisture and light. For shelf-stable purees, a common structure is PET/AL/PE, where aluminium foil blocks light and oxygen. Where foil is not wanted, PET/NY/PE gives good puncture resistance and a moderate barrier for shorter shelf life. Kraft paper laminates suit dry goods and a natural look, but they need an inner sealant layer.
Mono-material PE and PP recyclable structures and PLA/PBS compostable films are available, but their barrier is lower than foil laminates. Match shelf life to the material, not the other way around. If a product needs twelve months at ambient, test the chosen structure with real fill and real storage conditions before committing to print.
Filling, sealing and the add-ons that matter
Spouted pouches are usually filled through the spout or through the open top before the fitment is sealed. Corner spout and STANDCAP formats change how the pack stands and how the consumer dispenses. For dry baby cereal, a zipper plus tear notch is the practical minimum. A one-way degassing valve is only relevant for products that release gas, such as roasted coffee, not for purees.
Other add-ons include a window to show the product, a carry handle for larger formats, and a hang hole for retail pegs. Each addition affects web width, sealing area and run speed. Specify them at artwork stage. Adding a spout or zipper after print approval usually means new plates or new tooling, which adds cost and lead time.
What drives the unit price
Four things move the price: structure, print method, order quantity and add-ons. A three-layer foil laminate costs more than a two-layer PE structure. Rotogravure printing gives up to 10 colours at low unit cost on large runs, while digital printing suits short runs and frequent artwork changes. Adding a spout, cap or valve adds a component and an extra sealing step.
MOQ follows the print method. Digital printing starts from 100 pcs for pouches or 10 kg for film. Rotogravure starts from 10,000 pcs or 200 kg. Lead time is 10-15 working days for digital runs after artwork approval, and 20-25 working days for rotogravure. Stock pouch samples are free; the customer covers courier only.
Sustainability rules buyers should know
Recyclability depends on the whole pack, not one layer. A mono-material PE or PP pouch can fit existing recycling streams in some markets, but a mixed foil laminate usually cannot. Compostable PLA/PBS films need industrial composting conditions and should not be mixed with recyclable streams. Degradable options exist, but the claim must match the local test standard.
Check the rules for each market you sell into. Some countries require specific labelling for compostable or recyclable packs. Some retailers set their own targets. Ask the factory for the material declaration and any test reports before you print a sustainability claim on the pack.
Mistakes that cost time and money
The most common errors: choosing a structure before confirming the fill and process; approving artwork before the dieline is final; forgetting that spouts and zippers change the seal area; and assuming a stock pouch size will fit a new fill weight. Another is ordering rotogravure tooling for a product that may still change.
A simple checklist helps: confirm product form, process and shelf life; agree the structure and barrier; finalise the dieline and add-ons; approve artwork; then confirm MOQ and lead time in writing. Certifications such as BRC belong to the manufacturing partner, not to the supplier, so ask which factory will run the job and what it holds.