FAQ's

Tea is a natural, plant-based product that is exceptionally sensitive to external aromas and fragrances. Whether a blend contains flowers, bark, fruit, or spices, tea will readily absorb odours from surrounding products and environments, fundamentally altering its flavour profile and character. This makes aroma retention one of the most critical performance requirements in tea packaging.

Shelf life is equally important, as tea may sit in warehouses and on retail shelves for extended periods. A minimum shelf life of 6 to 12 months should always be targeted. The most effective materials for preserving loose leaf tea freshness are metalized polyester film, which provides strong aroma, moisture, and light barrier performance, and kraft paper pouches constructed to the 60/40 rule, where paper accounts for at least 60% of total packaging weight, which deliver both barrier performance and recyclability credentials. Swiss Pac offers both options across a wide range of tea pouch formats with full custom printing.

Tea is vulnerable to three key environmental threats, moisture, light, and odour, and the packaging structure must address all three effectively.

To protect against moisture, high-performance laminate films such as PE (polyethylene) or metalized film provide a strong moisture barrier, preventing the tea from absorbing humidity that causes clumping, mould, and flavour degradation.

To protect against light, which breaks down the natural compounds in tea and shortens shelf life, packaging materials such as white PE film, metalized film, or opaque coloured films are used. These block light from penetrating the pouch and degrading the product inside.

To protect against odour transfer, materials such as metalized PET, EVOH, and BOPA (biaxially oriented nylon) films provide an effective aroma barrier in both directions, locking the tea's natural fragrance inside while preventing external odours from entering. Swiss Pac incorporates these materials across its tea packaging range to deliver comprehensive protection against all three threats.

Yes, a barrier layer is essential in tea packaging. Tea contains delicate volatile compounds and aromatic oils derived from flowers, leaves, bark, and spices. These natural fragrances must be locked inside the pouch after sealing to preserve the tea's taste and aroma throughout its entire shelf life.

Without a barrier layer, aromatic oils escape through the packaging film and external odours can penetrate inward, both of which significantly reduce quality by the time the product reaches the consumer. The most effective barrier materials for tea packaging include metalized polyester (PET), EVOH, nylon, and PE. Swiss Pac uses these materials in laminated film structures that provide comprehensive, multi-layer protection tailored to the specific requirements of each tea product.

When packed in a correctly specified pouch with appropriate barrier materials, loose leaf tea , including blended teas, spiced teas, herbal teas, and flavoured teas, can stay fresh for between 6 and 12 months. The actual shelf life achieved depends on the barrier materials used in the packaging structure.

Higher-performance materials such as metalized polyester or EVOH laminates support shelf lives of up to 12 months, making them ideal for export, retail, and large-volume distribution. Standard barrier constructions typically deliver around 6 months of freshness. Swiss Pac works with each customer to specify the right material for their product, target market, and shelf life requirements.

There are four main printing technologies used in flexible packaging, each with distinct processes, advantages, and ideal applications.

Digital printing is the most innovative and fastest-growing technology in flexible packaging today. It requires no plates, cylinders, or moulds, the design is printed directly from the print head onto the packaging surface. This makes it exceptionally fast to set up, ideal for short runs, and capable of producing multiple different designs in a single production run without any tooling changes or additional costs.

Flexographic printing (Flexo) uses flexible polymer printing plates mounted onto rotating cylinders. The most advanced form is CI Flexo (Central Impression Flexo), where multiple colour stations are mounted around a single large central drum. Ink is transferred from the ink tray to an anilox roll, which then transfers it to the plate, and the plate applies it directly to the film surface. CI Flexo supports up to 10 colours and can print both sides of the film in a single pass using a turn-bar system, making it highly efficient for medium to high volume runs.

Rotogravure printing is one of the highest quality printing technologies available for flexible packaging. It uses a metal cylinder engraved with the design using a laser, coated with copper and then chrome-plated for durability. The cylinder is mounted in the printing machine, dipped in ink, and the engraved cells transfer ink directly onto the packaging film. After printing, the film passes through a curing chamber where the inks are heat-dried. Rotogravure delivers exceptional colour accuracy, consistency, and print quality, making it the preferred choice for premium brands and high-volume production.

Screen printing is the oldest of the four technologies. It uses a mesh fabric screen, finer mesh for lighter ink density, coarser mesh for heavier ink transfer, through which ink is forced onto the packaging surface using a squeegee. Screen printing is a largely manual process, best suited for specific specialty applications rather than high-speed flexible packaging production.

Choosing the right printing technology depends on several factors specific to your product and business needs, including the type and style of pouch required, the print finish and effects desired, the materials being used, the quantity ordered, and the product being packaged.

The best way to determine the right technology for your order is to speak directly with the Swiss Pac sales team. Our specialists will ask the right questions about your packaging requirements and recommend the most suitable and cost-effective printing technology for your specific needs. Contact us today for a free consultation.

Technically, there is no strict minimum order quantity for digital printing. However, Swiss Pac recommends a minimum of 1,000 pieces per design to make the order cost-effective for the customer. Below this quantity, the per-unit price can become disproportionately high. Digital printing is ideal for startups, new product launches, seasonal designs, and brands testing new packaging before committing to larger production runs.

Yes, digital printing is approximately 30% more expensive per unit than traditional printing methods such as flexo or rotogravure. However, this cost difference is offset by significant advantages for short-run and startup orders. Digital printing requires no plate costs, no cylinder costs, and no tooling setup fees, meaning the total cost for small quantities is often considerably lower than traditional methods once setup costs are factored in.

The recommended approach for growing brands is to begin with digital printing to test designs, colours, and market response, then transition to flexo or rotogravure printing at scale to reduce per-unit costs significantly as volumes increase.

Yes, this is one of the most valuable advantages of digital printing for flexible packaging. Because digital printing requires no plates or cylinders, multiple different designs, flavour variants, sizes, or SKUs can be printed in a single production run with no additional tooling costs or setup time between designs.

This makes digital printing the ideal choice for brands with multiple product variants, limited edition packaging, personalised designs, or those launching several SKUs simultaneously. Once initial designs are confirmed and volumes grow, brands can transition to traditional printing technologies to achieve greater cost efficiency at scale.

Yes, rotogravure printing is absolutely worth the investment once your brand is ready to scale. Compared to other traditional printing technologies, rotogravure is approximately 30% cheaper per unit at volume, making it one of the most cost-efficient long-term printing solutions available for flexible packaging. The upfront investment in printing cylinders pays for itself quickly as order volumes grow, and the consistency and quality of output means fewer reprints, less waste, and a more premium result on shelf. Swiss Pac recommends rotogravure for any brand that has established its design, confirmed its market, and is ready to commit to larger production runs.

The cost of rotogravure cylinder setup typically ranges from $6,500 to $14,000, depending on the size of the packaging, the number of colours in the design, and the monthly production volumes required. While this is a meaningful upfront investment, it is a one-time cost that delivers significant per-unit savings over the lifetime of the production run. For brands producing at scale, the cylinder cost is recovered quickly through lower printing costs compared to digital or flexo alternatives. Swiss Pac's sales team can provide a precise cylinder cost estimate based on your specific packaging size, design complexity, and projected order volumes.

Rotogravure printing delivers exceptionally high colour accuracy and consistency, the highest of any printing technology currently used in flexible packaging. Full Pantone PMS colour matching is supported, meaning your brand colours are reproduced precisely and consistently across every production run, regardless of volume. The engraved cylinder technology ensures ink is transferred uniformly to the packaging surface every time, resulting in vibrant, bright, and clean colours with minimal variation between batches. For premium brands where colour consistency is a non-negotiable brand standard, rotogravure is the recommended technology.

The right choice depends entirely on where your brand is in its growth journey. Digital printing is the ideal starting point, it requires no cylinder or plate investment, supports very low minimum order quantities, and allows you to test designs, colours, and formats quickly and cost-effectively. Rotogravure printing becomes the better choice once your brand has established its packaging design and volumes are large enough to justify the cylinder investment. At that point, rotogravure delivers superior colour quality and is approximately 30% cheaper per unit than digital, making it significantly more cost-efficient for large and ongoing production runs. Many Swiss Pac customers begin with digital printing and transition to rotogravure as their business scales.

Both flexographic and rotogravure printing are high-quality technologies, and both are widely used in flexible packaging production. However, rotogravure consistently delivers a higher quality print result than flexo, particularly for complex designs, photographic imagery, and fine detail work. The engraved cylinder in rotogravure transfers ink more precisely and uniformly than the polymer plates used in flexo, resulting in sharper images, more vibrant colours, and greater consistency across long production runs. For brands competing at a premium level where print quality is a key differentiator, rotogravure is the preferred technology.

Rotogravure printing delivers the best colour output for premium flexible packaging. The cylinder-based ink transfer process produces exceptionally vibrant, bright, and clean colours that are difficult to match with other printing technologies. The depth and consistency of colour achieved with rotogravure gives packaging a high-end, polished appearance that positions products effectively in premium retail environments. For brands where shelf presence and visual impact are critical to purchase decisions, rotogravure is the definitive choice.

Digital printing has the lowest setup cost of any printing technology, in fact, it has zero tooling setup cost. There are no plates to produce, no cylinders to engrave, and no setup waste generated. This makes digital printing the most accessible and cost-effective entry point for new brands, startups, and businesses testing new packaging designs or launching multiple SKUs simultaneously. The absence of setup costs means the full order cost goes directly into producing the actual packaging, making digital printing exceptionally economical for short runs and first-time orders.

Digital printing is the clear winner for small batch and startup orders. With no cylinder or plate investment required, no minimum tooling fees, and a recommended minimum of just 1,000 pieces, digital printing gives new brands and small businesses full access to high- quality custom printed packaging without the financial commitment required by traditional methods. It also offers the flexibility to print multiple designs or SKUs in a single run, making it ideal for brands launching with several product variants or flavours. Swiss Pac recommends digital printing as the natural starting point for any brand new to custom flexible packaging.

Rotogravure printing is the best technology for high-volume and large-scale packaging production. Once the cylinder investment has been made, the per-unit printing cost drops significantly, making rotogravure approximately 30% cheaper than other technologies at scale. The consistency, speed, and colour quality of rotogravure also make it ideal for brands supplying large retail chains, export markets, or high-turnover product lines where both volume and quality standards are demanding. For established brands competing at scale, rotogravure offers the best combination of quality, consistency, and long-run cost efficiency available in flexible packaging today.

No, the print quality on foil pouches is equivalent whether produced using digital or rotogravure printing. Both technologies are fully compatible with foil substrates and deliver excellent results on metalized and aluminium foil packaging materials. The choice between digital and rotogravure for foil pouches should therefore be based on order volume and cost considerations rather than any difference in achievable print quality. Swiss Pac produces foil pouches using both technologies to the same high quality standard.

Rotogravure printing is the best technology for reproducing photorealistic images on flexible packaging. The laser-engraved cylinder process captures extremely fine detail and reproduces complex photographic imagery with high resolution, sharp definition, and accurate colour gradients. For packaging designs that feature food photography, lifestyle imagery, or any detailed visual content where image quality is central to the brand's shelf appeal, rotogravure delivers the highest possible standard of photorealistic print reproduction.

Digital printing is currently the most sustainable and eco-friendly printing technology for flexible packaging. Because it requires no printing plates, no engraved cylinders, and no tooling setup process, digital printing generates significantly less raw material waste than traditional methods. In conventional printing technologies such as flexo and rotogravure, the setup and colour calibration process itself generates considerable material waste before a single saleable unit is produced. Digital printing eliminates this entirely, ink is applied directly to the packaging surface from the first unit, resulting in zero setup waste. For brands with sustainability commitments, digital printing is the most environmentally responsible choice for short to medium run flexible packaging production.

Any type of snack food needs to be protected from oxygen for longer shelf life. If the product comes into contact with oxygen, its taste can go bad, and the crunchiness and freshness of the product can decrease.

The product should also stay away from moisture. If moisture comes into contact with the product, the crispiness and crunchiness can be lost.

So, for snack food packaging, two things have to be taken care of: moisture and oxygen.

There are many different materials available to provide a barrier and protect the product from oxygen and moisture.

The first material is PET/PE. It is a normal barrier option where the product is not highly prone to oxygen and moisture, and if the customer requires a window to see the product, PET/PE is one combination.

The second combination is PET/CPP. If the customer wants high transparency and high clarity, where they want to show the product in a crystal-clear bag, PET/CPP is a good option. For bakery products or snacks that are highly sensitive to moisture and are not very heavy, PET/CPP provides very good transparency. For smaller snacks, such as up to 250 or 300 grams, PET/CPP is a good option because the window is very clear and transparent, giving a crystal-clear look. The product inside also looks fresher.

If the customer does not want a window and requires a metallized layer, we can provide a metallized layer. A matte-finish BOPP metallized PET/PE structure is an option where light sensitivity is a concern, as some products deteriorate faster when exposed to light.

When metallized polyester/PET structures are used, the light barrier is also good, the moisture barrier is good, and the oxygen barrier is very good.

If the customer wants a window with a very high oxygen barrier, we can use PET and EVOH PE. EVOH is very good for oxygen barrier while still allowing a window. EVOH is used for products that need to stay fresh for a very long time.

Another option is ALOX PET/PE, which is also used in many high-barrier window bags and transparent bags.

One more option is CPP with surface printing. If the customer wants a very cheap product, or if the product is packed in secondary packaging and the primary product inside is very lightweight, we can print directly on CPP using surface printing. This is a very economical option.

The shelf life of snacks depends on the packaging material and how well the packaging protects the product.

When the right material is used and the packaging is leak-proof and airtight, the shelf life of the product can be increased by at least six to eight times.

For example, if an unpackaged product stays fresh for five days, properly packaged food can sometimes have its shelf life multiplied by six to eight times.

It is very important for any food product to be packed in a technical way to increase shelf life. Snacks require both an oxygen barrier and a moisture barrier. If these two requirements are met, the product life is increased drastically.

For snack food, a stand-up pouch is a good option if the product is in a bigger pouch, such as 250 grams or more, maybe 500 grams up to 1 kilo.

If it is a family-size pack, the product would not normally be consumed in one time. In that case, a stand-up pouch with a zipper is a good option. The zipper helps prevent moisture from going inside and helps the product stay fresh for a longer time.

The zipper is also useful when somebody wants to carry the package while travelling. If the package is not consumed in one go, the customer can eat some of the product, zip the pouch again and keep it. There is no spillage, and it is easy to carry and handle. A zipper is a user-friendly option, and the sales potential can be higher when pouches have a zipper.

The second option is a flat-bottom pouch. Flat-bottom pouches are used for snack foods where the product is very premium. If the product needs to stand very nicely on the shelf and have a neat, clean and luxurious look, a flat-bottom pouch with a zipper is a good option.

A side-gusset bag, or a Quad Seal pouch, can be used where the product is more like a powder or consists of grains or very small granules. However, technically, I would consider it a less suitable option for snack products. Better options are the standard stand-up pouch and the flat-bottom pouch.

A three-side-seal pouch with a zipper is also a good option for smaller products, such as 100, 150 or 200 grams. It provides a nice display, and if the pouches are given inside a box as small inner packaging, a three-side-seal pouch is also a good option.

Pillow pouches are a big hit for snacks that are consumed only once and then thrown away, such as potato chips. For any snack item intended for single-time consumption, pillow pouches are the most user-friendly and cheaper option. The best cheaper option is a pillow pouch.

A stand-up pouch is designed to stand on the shelf, so the visibility is very nice and the selling prospects are very good. Because it stands on the shelf, the customer can easily see the pouch and the product presentation. It is also very easy to use because it has a zipper.

So, for snack food packaging, a stand-up pouch would generally be a better option where resealability and shelf presentation are important.

Pillow pouches are different. If the product is intended for one-time, single-use consumption, the pillow pouch is the cheapest and most convenient option. Many snacks are consumed only once, so there is no need for a zipper.

Stand-up pouches are more expensive, whereas pillow pouches are suitable where there is single-time use.

Yes, definitely. If the snack is visible from outside, especially if you are packing cashews or other nuts, it is good to show the customer the nuts and their size.

A window is a good option for snack foods and nut packaging because the customer can see the product before buying it.

When it comes to a window, I would recommend PET/CPP as the best option for snack food because CPP has a very high moisture barrier. The snack packed inside can remain crispier for a very long time. PET/CPP also makes the pouch and product look very fresh and newly made.

PET/PE pouches can look slightly hazy in the window, which can make the product inside appear old. PET/PE also does not have the same moisture barrier as PET/CPP.

However, CPP has one disadvantage: it does not have very high strength. When there is more weight inside, it may not pass a 10-drop test. This is one limitation.

But there are many good points, and I would consider PET/CPP a good option for packing snacks with a window.

If you are exporting and require a very long shelf life and foolproof packaging, foil lamination for snacks is the best option.

For fried foods or fried snacks, especially snacks containing nuts, aluminium foil can be the best option because nuts can deteriorate faster than many other snack products.

If you require a shelf life of more than four or six months, aluminium foil-based laminations can increase the shelf life drastically. Aluminium foil/PE can be an option, and paper/aluminium foil/PE can also be an option.

Another option is paper/aluminium foil/CPP. Polyester/aluminium foil/CPP can also be an option.

For a longer or extremely high shelf life, and especially if you are exporting and want to reduce the risk of the product's taste changing or the product going bad faster, aluminium foil lamination is recommended.

Yes, definitely. Swisspack is known for custom printed snack food packaging for brands.

If you are starting or launching a brand, especially as a startup, Swisspack can provide custom snack food packaging. Swisspack exports its products to more than 70 countries and is a quality producer and manufacturer of snack food packaging. Swisspack is also the largest stand-up pouch manufacturer and flat-bottom pouch manufacturer in India at this moment.

Swisspack has digital printing, flexo printing, Gravure printing and static printing, such as screen printing. It has all four technologies in-house.

If you are a startup, you can start with Swisspack using digital printing, which has lower minimum quantities. However, the price of digitally printed pouches is higher.

Once you understand your product, ingredients and design and your quantities become bigger, you can come back to Swisspack and move to another technology. Swisspack can shift you to Rotogravure or Flexo, without changes to the design.

Your pouches can be at least three to four times cheaper than digital printing, allowing you to save a lot of money.

So, when you are a startup, the best approach is to start with Swisspack and use digital printing. Once your quantity becomes bigger, you can migrate to Flexo or Gravure and save money.

For snack food packaging, there are lots of printing and finishing options available.

These include:
• Matte finish
• Matte and gloss effects, including spot UV or spot varnish
• Fully matte, 100% matte
• Matte with soft touch
• Fully high-gloss effect
• Gloss effect with a window
• Matte-finish printing with a window

Soft touch is also a great option, particularly with a matte finish.

We can also provide kraft paper printed options with foil lamination, which can provide very good shelf life. Even with paper, you can have an earthy, handmade or artisan effect for a very premium look.

We can also provide paper packaging with a window so the customer can see the product.

There are many options for snack food startups when it comes to printed packaging and finishing. Swisspack can offer these printing effects and packaging options in India.

Yes. We have an option called digital printing, where you can print a minimum of 1,000 pieces in one design.

If you have 20 or 30 different snack food designs for different flavours, and you are a startup, digital printing is a good option. At the startup stage, you may not know whether there will be changes in the design or ingredients, especially when there are multiple ingredients and regulations or laws are changing.

So, when you are a startup, go for digital printing. Invest in 1,000 pouches in each design and start with Swisspack using digital printing.

As you grow and your quantities increase to perhaps 2,000, 3,000 or 10,000 pouches, you can shift from digital to Gravure or Flexo. This can save you a lot of money.

So, for different flavours, you can start with digital printing with a limited budget and then move to Rotogravure or Flexo when you want to save money.

Yes. There are multiple eco-friendly and sustainable options for snack food packaging.

The first is plastic-free packaging. We use 100% paper with a barrier coating inside the paper, and heat-sealable paper can be used to pack certain snack foods.

The second option is PCR packaging, which is made out of waste. We collect waste, recycle it and then make the pouches from it. Technically, this helps in cleaning the planet.

The third option is fully recyclable packaging. This is a very good option because you can get a very good barrier, long-term shelf life and user-friendliness. Everything is there, and it is not very expensive.

If you are looking for a sustainable packaging option, fully recyclable packaging is a good choice. This recyclable packaging can be printed using Rotogravure, digital printing and Flexo printing.

If you have 1,000 pieces as a minimum, we can do it. When you grow, we can shift you to Rotogravure and Flexo and save you a lot of money.

No. Kraft paper snack bags are not recyclable when they have multilayer laminates inside.

Technically, because of the multilayer laminate structure, this type of kraft paper snack bag is not recyclable.

The minimum order starts from 1,000 pieces for digital printing.

As you grow, you can shift to Rotogravure or Flexo. For Rotogravure and Flexo, the minimum order starts from approximately 5,000 to 10,000 pieces.

You can save a lot of money if you move to Rotogravure or Flexo at quantities of around 10,000 pieces.

So, when you are a startup, you can start with digital printing and then move towards Rotogravure and Flexo as your quantity increases.

Swisspack is the only company that does all the packaging technologies in-house. When you are shifted from one technology to another, you should not see a difference in printing quality or technology. The colours can completely match.

This is a key point when selecting Swisspack. When you shift from one technology to another, the shade difference is not there, so your customers will not get confused about the colours or feel that you are using packaging from a different or duplicate company.

The right pouch size can be selected by physically filling the product inside the pouch.

If you are a startup, you can go to Swisspack.com or Swisspack.co.in and request a free sample. There is a request-for-free-sample option on the website.

You can request free samples, and we can send you a full kit containing stand-up pouches, flat-bottom pouches, three-side-sealed bags and other pouch formats.

We have sizes ranging from approximately 28 grams to 5 kilos, with multiple different sizes. For stand-up pouches, we have around 13 standard sizes.

You should physically fill your snack food into the different sample sizes and check which size is suitable for your product.

For example, depending on the product, a particular pouch size can hold a different quantity. So you should check your actual product by filling the sample pouch.

You can test the product in a stand-up pouch, flat-bottom pouch, Quad Seal pouch or three-side-seal pouch and see which size suits you best.

After selecting the size, you should also leave some empty space at the top. The pouch should not be completely full. Around 25% to 35% empty space should be maintained so that the pouch does not look excessively full or oversized.

After checking the samples and selecting the appropriate size, you can place your order with us.

Yes, you can order samples from the Swisspack.co.in or Swisspac.com website. There is a request-for-free-samples option, so you can order free samples before placing your bulk order.

Before confirming the size, you can order the samples and check them.

As soon as you receive the samples, you should first fill your actual product physically into the pouch and check which size suits you.

You should also make sure that approximately 25% to 35% empty space is maintained at the top of the pouch. The pouch should not be filled completely.

Once you have checked the product and selected the appropriate pouch size, you can choose the size and place your order in bulk.