Filling liquids, powders and granules in flexible packaging

Each one places different demands on dosing, sealing and pack handling, so machine choice needs to start with product behaviour rather than pack appearance alone.

A liquid needs controlled filling and dependable seals. A powder needs accurate dosing and good control over flow and dust. Granules need consistent portioning without slowing the line or damaging the product.

That is why the right machine is usually the one that matches both the product and the pouch format being used.

Liquids and semi-liquids need a filling system that can control volume accurately and keep the seal area clean. Thin liquids, thicker sauces and more viscous products all behave differently, so the filling method needs to reflect that.

For smaller packs, sachet and stickpack machines are often a strong choice. They suit single-serve or compact formats where speed and consistency matter.

Where the product is better suited to a larger, more retail-ready pouch, doypack machines are a great choice. This format works well when the pack needs to stand on shelf, hold a larger volume or include added features such as spouts or resealable closures.

Powders can work very well in flexible formats, but dosing needs to be tightly controlled. Fine powders and products that settle or bridge can quickly affect fill accuracy if the setup is not right.

For smaller-format packs, sachet and stickpack machines are often the natural starting point. They are well suited to single portions and convenience-led formats.

If the product needs a larger pouch with stronger shelf presence, doypack or premade pouch formats may be the better route. This is often the case for dry goods that need a retail-ready finish rather than a compact single-serve pack. Find out more about the machines designed for this format in more detail on our doypack machines page.

Granules sit somewhere between powders and larger solids. They need accurate portioning, but product size, shape and fragility can also influence the right machine setup.

Sachet and stickpack formats can work well for smaller granular products where compact flexible packs are needed. For larger pouches, weighers or pouch systems may be more suitable, particularly where pack presentation or resealability matters.

Granular products can also be a good fit for doypack when the pack needs to stand up well on shelf and offer a more convenient user experience.

Doypack is worth considering when the pack needs to do more than simply contain the product. It is usually better suited to stand-up pouches, larger formats and retail-facing packs where presentation, convenience and pack stability matter.

This makes it a strong option for:

• liquids and semi-liquids that need a larger pouch format
• powders that need a stand-up retail pack
• granules and dry goods where resealability is useful
• manufacturers moving beyond small single-serve formats

Whilst sachets and stickpacks are often better for compact, high-speed packs, doypack is often better where the pouch needs more presence and functionality.

The most useful way to choose is to look at five things together: product behaviour, pack format, dosing accuracy, sealing requirements and output targets.

If the product is a liquid going into a small portion pack, sachet or stickpack may be the best fit. If it needs a larger stand-up pouch, doypack is often more suitable. If the product is a powder or granule and the aim is a compact format, sachets and stickpacks can work well. If the same product needs a larger, retail-ready pouch, a pouch-based system may make more sense.