If you’ve ever struggled to open a packet without scissors, you’ll know how irritating it can be. Now imagine that happening with your product in the hands of your customers. First impressions matter, and bad packaging can quickly sour the experience.
That’s a challenge many brands face as they move towards recyclable mono-material films such as polyethylene (PE) and polypropylene (PP). These materials are strong, lightweight, and better for recycling in the UK, but that extra strength can make them harder to tear. Without the right design features, customers may tug at the pack, stretch it out of shape, or even damage the resealable closure.
This is where laser scoring in flexible packaging comes in. It’s a small but important detail that can make your pack easier to open, more professional to handle, and more reliable in day-to-day use. At Aropack, we integrate laser scoring into pouch packaging designs to ensure both usability and sustainability go hand in hand.
How Laser Scoring Works
Laser scoring is exactly what it sounds like: using a fine laser beam to create a controlled line on the outer layer of your packaging film. This line acts as a guide for the tear, making it smooth and predictable.
Importantly, the laser doesn’t cut all the way through. The inner barrier layers, which protect against moisture, oxygen and UV light. This means your product’s freshness and shelf life aren’t affected.
The scoring line can be placed in a straight line across the top, just above a zip, or along one side for a directional tear. On printed plastic bags for food packaging, it can be aligned perfectly with your artwork so it blends in. Done right, it’s invisible until someone opens the pack.
Why Recyclable Films Need Extra Help
Traditional laminated films (with PET, foil or metallised layers) have a natural tendency to tear once started. Mono-material PE and PP don’t. They stretch first, then tear unpredictably. This is especially problematic for:
-
Easy-open pouches – customers expect quick, neat access.
-
Resealable plastic bags – a bad tear can ruin the closure.
-
Sachet packaging – single-use packs that shouldn’t require tools to open.
By adding laser scoring to your flexible packaging, you take control of the opening process. You choose exactly where and how the tear happens. For resealable pouches, this often means the score line sits just above the zip, so the closure remains fully functional after opening.
Where Laser Scoring Makes the Most Difference
From our experience at Aropack, the benefits are most noticeable in:
-
Sachet packaging – powders, sauces, and samples open cleanly without tearing unevenly.
-
Resealable plastic bags – closures stay intact and customers can reuse them with ease.
-
Premium printed plastic bags for food packaging – functionality improves without spoiling the look.
-
Large-format pouch packaging – even thick films gain consistent pouch tear performance.
When Aropack designs packaging for clients, we look at the full picture , from material choice to tear path, so opening is as smooth as possible for the end user.
Design and Technical Considerations
Adding laser scoring isn’t just a case of “cut a line and done”. The position, depth, and style of the score must suit the material and the pack’s purpose. On pouch packaging with reseal zips, we make sure the tear starts above the closure but doesn’t compromise the seal.
The process also needs to be consistent in production. At Aropack, we work with precise laser systems that ensure the score is identical on every unit, which means no surprises when your customers open the pack.
For printed plastic bags for food packaging, design integration is key. The score can be placed to align with the graphics, making it almost invisible until it’s used.
Why It’s Worth Considering
A neat, easy-open pack sends the right message: your brand cares about the details. And when combined with recyclable films, it shows you’re committed to sustainability without sacrificing the customer experience.
At Aropack, we’ve seen brands benefit from fewer complaints about pack opening, stronger repeat purchase rates, and improved perception in retail settings after adopting laser scoring flexible packaging. It’s not an expensive upgrade, but it can make your product feel better thought-out and more premium.
Wrapping Up
As more brands switch to sustainable materials, opening performance is becoming just as important as barrier protection or shelf appeal. Laser scoring is one of those small, invisible features that your customers may never notice consciously, but they’ll appreciate it every time they open your product.
If you’re planning to move to easy-open pouches, resealable pouches, sachet packaging, or premium printed plastic bags for food packaging, it’s worth talking to Aropack about how laser scoring flexible packaging can be built into your design from the start. Give us a call on 01233 281460 or send us an email at info@aropack.co.uk for a free consultation.