Material Structure and Thickness of Doypack

What is a doypack?

A doypack (also spelled Doy Pack or Doy-style pouch) is a type of flexible packaging pouch designed to stand upright on store shelves. It is widely used for food and non-food products because it combines the cost and convenience of flexible packs with the shelf presence of rigid containers.

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Main features of doypack:

The doypack has a gusseted bottom (or shaped base) that lets it stand upright when filled.

Typically made from multilayer laminated films (such as PET, PE, aluminum foil layers) that provide strength, barrier protection, and printability.

Can include heat seals, resealable zippers, spouts, tear notches, or screw caps for liquids.

Uses less material and takes up less volume in storage and transport than rigid packaging.

Large printable surface for branding and product information.

What does the material structure of doypack refer to?

Doypack is a type of flexible packaging product (i.e., flexible packaging bags). Like other flexible packaging products, their material structure is made by laminating different types of plastic films and compounding them. It is also one of the three major factors in determining the doypack price.

What are the common material structure combinations for doypack? What are their advantages and disadvantages?

Similar to the material structure of other flexible packaging bags, the material structure of doypack can be divided into three layers: “printing layer,” “barrier layer,” and “contact layer.” Although the number of material structures included in doypack can be as high as dozens, they still cannot deviate from one of the laws of flexible packaging bags (they can be composed and laminated from different types of plastic films, but this does not mean that these films can be combined into material structures at will). The following are common material structures suitable for (here we only discuss those non-spouted doypack; if you are interested in the material structures of those spouted doypack, you can click here).

PET/CPP(PE)

This material structure is suitable for fast-moving consumer goods (FMCG) (e.g., products that are insensitive to oxygen, moisture, and sunlight). It is not suitable for packaging liquid products larger than 200g/ml. When CPP is used as the contact layer, it is not suitable for packaging liquid products, but the doypack, has higher stiffness.

PET/PET/CPP(PE)

Doypack with this material structure offer moderate barrier properties against oxygen and moisture, but lack sunlight protection. They are suitable for packaging products weighing less than 1000g/ml. When CPP is used as the contact layer, they are not suitable for packaging liquid products, but the bags offer increased stiffness.

PET/VMPET/CPP(PE)

This material structure offers moderate barrier properties to oxygen and moisture, but offers excellent barrier properties to sunlight, making it suitable for packaging products under 1000g/ml. When CPP is used as the contact layer, it is not suitable for packaging liquid products, but the doypack, has higher stiffness.

PET/Kraft paper/CPP(PE)

This material structure offer excellent barrier properties against moisture, but other properties are average. They are best suited for packaging moisture-sensitive products such as coffee beans and ground coffee. When packaging products weighing less than 500g/ml, PE is the contact layer; when packaging products weighing more than 500g/ml, CPP is the contact layer.

PET/NYLON/PE

This material structure offers moderate barrier properties to oxygen and moisture. Although, like PET/PET/PE, it does not block sunlight, its superior pressure resistance makes it suitable for packaging products under 5000g/ml.

PET/AL/CPP(PE)

Doypack with this material structure offer the best barrier properties against oxygen, moisture, and sunlight, and possess excellent sunlight protection. The major drawback is that these bags are relatively expensive. When CPP is used as the contact layer, they are not suitable for packaging liquid products, but the bags offer increased stiffness.

MOPP/PET/CPP(PE)

This material structure for doypack has the same functions and drawbacks as PET/PET/PE, but the printed layer can be given a matte finish. When CPP is used for the contact layer, it’s not suitable for packaging liquid products, but the bag does offer increased stiffness.

What does the thickness of the material structure in spouted pouch refer to?

It refers to the total thickness of the “printing layer,” “barrier layer,” and “contact layer” on one side of the pouch. Thickness is measured with calipers at the midsection of the pouch, offset slightly left or right, then divided by two. For example, if the measured value is 248 microns, divided by two equals 124 microns; the net thickness should be considered 120 microns because about 4 microns accounts for adhesive and solvent residue between layers and is excluded from the calculation.ls, as authentic endorsements from satisfied customers, serve as potent social proof, significantly inspiring trust in potential consumers.

How is the thickness of a doypack’s material structure determined?

Due to the wide variety of materials and suitable contents used for doypack, determining their thickness is often irregular. If it is launching your doypack project for the first time, it’s recommended to reference the thickness of market competitor bags or inquire with your partner doypack manufacturer.

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