A flexible packaging supplier can look like the perfect fit when you are comparing quotes. The unit price is competitive. The lead time sounds manageable. The samples look spot on. Everyone is responsive, and the whole project feels straightforward. Then you place the first order and reality shows up. The colour is slightly off from what you approved. The seals do not behave the same way on your line. The “same spec” turns out to have a few quiet changes in it. Or an artwork slip turns into a labelling headache you really did not need.
This post is here to answer a simple question: how do you choose a flexible packaging supplier in a way that protects your operations and your brand, not just your unit cost? Most costly packaging problems are not random. They follow familiar patterns. Which is good news, because familiar patterns can be managed with the right checks. At Aropack, this is exactly how we approach projects, we treat supplier performance as a system you can verify, not a promise you can hope will hold.
Why “Cheap” Can Get Expensive Very Quickly
Flexible packaging rarely fails in a dramatic way. It fails in the most annoying way possible: it slows everything down. A launch gets pushed. Finished goods get held while people look for paperwork. A retailer rejects a pallet. A few customer complaints turn into a bigger conversation about traceability, specifications, and whether the pack is actually compliant.
There’s also a reason established brands take this so seriously. Industry benchmarks often quote average direct recall costs around $10 million, before you get into the longer tail of lost sales and brand damage. Even without recall-level drama, labelling mistakes are a known route into serious problems, especially with allergens. A major review of global data identified 2,470 recalls and alerts linked to labelling errors, with undeclared allergens as the most common driver. So the goal is not to overthink every supplier. It’s to ask the right questions early, while it is still easy to change course.
What to Expect From Your Flexible Packaging Supplier
A packaging supplier can only be “good” if you define what good looks like for your product. Different products punish packaging in different ways. A dry product can quietly pick up moisture and go soft. Oily products can expose weak seals and scuff resistance. High-aroma products can lose their punch if barrier choices are wrong. Then there’s the packing line itself. A pouch that behaves fine when hand-packed can become a problem at higher speeds where sealing windows are tighter.
Before you judge any flexible packaging supplier, get these four things clear and keep them written down.
- Your product risks. Think oxygen, moisture, light, aroma loss, grease migration, contamination during filling, puncture risk.
- Your format and features. Doypack, flat bottom, quad seal, sachet, flow wrap, lidding film, spouts, zippers, valves.
- How you pack. Filling method, sealing jaw type, target line speed, and whether product contamination can hit the seal area.
- Your non-negotiables. Shelf life, barrier, sustainability restrictions, and compliance requirements for your market.
If this feels like a lot, that’s normal. It is also where a good partner earns their keep. At Aropack, we routinely help brands translate those inputs into a practical structure and specification, so everyone is working from the same reality, not assumptions.
Food Contact Compliance and Traceability
If the packaging is for food or pet food, “food grade” is not enough. You need proper documentation, and you need traceability that does not fall apart the moment someone asks for proof. At EU level, the framework regulation for food contact materials is Regulation (EC) No 1935/2004, including traceability requirements in Article 17.
In plain terms, ask for a Declaration of Compliance for the exact structure you are buying, not a generic statement. Ask how traceability works across printing, lamination, and conversion. At Aropack, we keep the conversation evidence-led from the start, so compliance and traceability are built into the project rather than stitched on at the last minute.
Print and Ink Governance
Ink and adhesive risk is one of those topics brands tend to ignore until they cannot. And by then, it is often too late to fix cheaply. You may also hear suppliers reference the Swiss Ordinance framework, often used as a benchmark in ink compliance discussions.
Ask what ink and adhesive standards they follow and whether they can support product-specific migration assessment. A good flexible packaging supplier won’t dodge this. They will explain it clearly, including what is achievable for your structure, your shelf life, and your storage conditions.
At Aropack, we see this as part of responsible project guidance. It is not about making things sound complicated. It is about preventing avoidable surprises once packs are already printed and converted.
Certifications That Mean Something in Real Life
Certifications are not magic. But they can be a strong signal that your packaging supplier runs disciplined systems, especially around document control, traceability, and corrective actions In the packaging world, you will often see BRCGS Packaging Materials, IFS PACsecure, or FSSC 22000 for packaging manufacturing. If you are auditing suppliers around now, it is also worth knowing that BRCGS Packaging Materials Issue 7 audits commence on 28 April 2025 after a transition period.
Change Control
Most painful flezible packaging problems happen because something changed and nobody told you. That change might be resin, film gauge, adhesive system, a valve component, or remade cylinders that shift colour. It might be a “small” artwork update that slips through. You only discover it when product is packed and you are under pressure.
So change control is non-negotiable. You want a written process that defines what counts as a change and confirms that changes are not implemented without your approval. Ask for their change control policy. Ask for examples of changes that require sign-off. Ask how they protect repeat-order consistency. This is a big part of how Aropack runs projects, because a pouch that performs beautifully once is not enough. The goal is to make performance repeatable, order after order.
Quality Control You Can Measure
Quality should not be a vibe. It should be measurable. At minimum, you want routine controls around film thickness, print registration, colour consistency, visible defects, and release criteria. Better flexible packaging suppliers keep retained samples and follow a proper complaint-to-CAPA process, so repeat problems do not keep returning.
At Aropack, we lean into this kind of transparency. When buyers ask for measurable controls, it usually means they care about long-term performance, and that is the kind of relationship that avoids silly, expensive surprises.
Artwork Control and Allergen Risk
If your product contains allergens, packaging becomes part of your safety system. That is not overdramatic, it is reality. The UK Food Standards Agency has described a case where sausages containing gluten were dispatched with sleeves labelled gluten free, driven by a packaging control failure rather than a recipe change.
Aropack takes artwork governance seriously because it is one of the easiest areas to underestimate. When it is handled properly, nobody notices. When it is handled poorly, everyone notices.
Lead Times of Your Flexible Packaging Supplier
A flexible packaging supplier can be technically strong and still cost you money if delivery performance is shaky. Late packaging is not a mild inconvenience, it can halt production, trap cash in finished goods, and force you into expensive freight and last-minute decisions. We suport projects with practical operational options, including storage for larger-volume orders which helps brands avoid both stockouts and over-order panic.
Sustainability Without Greenwashing
Sustainability in flexible packaging is no longer just about brand preference. In the UK flexible packaging industry, it can directly affect compliance, reporting, and cost. The UK Plastic Packaging Tax applies to plastic packaging components with less than 30% recycled plastic, and government guidance is clear that plastic is assumed virgin unless evidence shows recycled content was used. Packaging EPR is also landing as a direct cost. Government guidance on 2025 base fees notes invoices sent to producers in October 2025.
At Aropack, we focus helping brands choose sustainable flexible packaging solutions that make sense for performance and for real-world UK recycling routes, while keeping sustainability claims grounded in what can actually be evidenced.
A Practical Way to Choose the Flexible Packaging Supplier
A strong flexible packaging manufacturer is rarely the one who promises the most. It is usually the one who can prove control in the unglamorous areas: traceability, change control, testing discipline, artwork governance, and corrective actions. Price matters. But in day-to-day operations, the “cheapest” packaging is the one that runs cleanly, arrives reliably, protects shelf life, stays compliant, and does not create avoidable stress.
If you want a practical shortcut, choose the flexible packaging company who makes your project more predictable. That is the spirit behind how Aropack works, we aim to reduce decision risk early, rather than leaving you to discover issues when you have already committed budget, stock, and launch plans.
Conclusion
Choosing a flexible packaging supplier is ultimately a risk decision disguised as a buying decision. If you want to prevent costly problems, anchor your choice in evidence. Look for compliance and traceability you can audit. Insist on change control to prevent silent drift between sample and production. Choose measurable quality control, not vague reassurance. Treat sustainability claims as proof-based, especially in the UK.
If you need a flexible packaging supplier who keeps things clear, calm, and properly controlled, Aropack is a solid place to start. We help UK and Europe-based brands choose the right pouch structure for their product, keep artwork and specifications consistent from sample to production, and make sure nothing important gets “lost in translation” along the way. The goal is simple: packaging that performs reliably on your line and on shelf, with a process that feels straightforward, not stressful.
If you’d like to explore the best flexible packaging solutions for your business, we are here to help. Give us a call on 01233 281460 or send us an email at info@aropack.co.uk for a consultation. Let us help you find the perfect balance between sustainability and functionality.
