Custom printed pouches can give your brand serious shelf appeal, when done right. But too often, small missteps early in the ordering process lead to expensive delays, disappointing finishes, or packaging that doesn’t work as intended.
Whether you’re a startup placing your first pouch order or a seasoned team refreshing your packaging, avoiding these common mistakes can save time, money, and a few headaches.
Let’s walk through common pitfalls brands face when ordering custom printed ziplock bags, printed plastic bags with logo, and eco-friendly custom pouch packaging and how to sidestep them like a pro.
Not Knowing Your Quantities or How They Affect Print Options
A small run and a large run aren’t treated the same in the packaging world. Quantities affect not only your unit cost, but also your printing method, lead time, and material choices.
For instance, digital pouch printing is great for short runs and multiple SKUs, it allows full-colour flexibility without plate costs. Gravure, on the other hand, is ideal for high volumes with consistent design.
Not being clear on your order size (or how it may grow over time) can lock you into a less-than-optimal setup. At Aropack, we help you choose what’s most cost-effective for your volume.
Leaving Print Files to the Last Minute
Your packaging design is more than just a logo slapped on a bag. It needs to be high-resolution, CMYK, correctly formatted, and adapted to the actual shape and size of your custom printed pouches. This isn’t something to sort the day before production.
We’ve seen delays and reproofs just because the wrong file type was sent or bleed margins were missing. Having your print-ready files locked in early gives you more control and avoids costly back-and-forths.
Choosing the Wrong Material for Your Product
Not all printed food pouches are created equal. Your product’s shelf life, texture, and sensitivity to light or moisture will impact the ideal material structure. A granola pouch? Different to protein powder. Pet treats? Different again.
At Aropack, we guide you through whether you need high-barrier layers, recyclable films, or something in between. Choosing the wrong structure can mean shorter shelf life, more returns, or extra waste.
Overlooking Practical Features Like Zippers and Tear Notches
Custom printed ziplock bags often sound simple until you forget to specify how they open, reseal, or tear. Consumers care about ease of use more than you might think. Bad user experience? Your beautiful branding won’t save you.
We always ask clients: Do you want standard zip or powder-proof? Need laser scoring for a clean tear? Let’s think it through at the start.
Not Planning for Your Fulfilment Process
Some brands focus so much on the print and pouch size, they forget about the filling line. If your co-packer struggles to open, fill, or seal the bags efficiently, you’re in trouble.
A stand-up pouch that looks great but topples over during filling? Not ideal. We help you choose structures that run smoothly on your equipment, not just on screen.
Ignoring Lead Times (and Missing Launch Deadlines)
Packaging printing companies like ours do everything we can to keep timelines tight, but there are realities: digital print takes 4 to 5 weeks; gravure can take 10 to 12 weeks. Add in festive seasons, material sourcing delays, or design revisions, and you’re quickly in trouble.
We always encourage early planning and realistic expectations. Rushing can lead to errors. Worse, it can delay your product launch.
Assuming Eco-Friendly = One-Size-Fits-All
There’s a lot of greenwashing in the eco-friendly custom pouch packaging space. Recyclable, compostable, biodegradable, they’re not interchangeable.
We’ll help you choose solutions that are not just good on paper but work for your product, your brand, and the recycling infrastructure of your customers.
Our recyclable mono-material pouches (PE or PP) are a sustainable solution that doesn’t compromise barrier protection. But we’ll also tell you when something compostable packaging won’t be a fit.
Not Getting Physical Samples
Packaging mockups on screen can be deceiving. Colours don’t always print as expected, and the feel of the pouch, thickness, finish, rigidity matters more than you think.
We always recommend getting physical samples before mass production. It’s the best way to ensure what you think you’re ordering is actually what you’ll get.
Letting Someone Else Handle Your Branding Without Oversight
Whether you’re working with an agency or freelancer, you need to stay involved in the packaging process. Your custom pouch printing should align with your overall branding and logistics.
We’ve seen issues where lovely designs come through, but with barcodes too small to scan or claims that violate regulations. Keep your eye on the full picture.
Not Partnering with the Right Packaging Specialist
There are many printing and packaging companies, but not all understand the ins and outs of printed plastic bags with logo, printed food pouches, and flexible, scalable production for growing brands.
At Aropack, we specialise in small to mid-sized runs, both digital and gravure, with the flexibility to store and dispatch over time. We don’t just print, we help you plan.
Final Thoughts
Ordering custom printed pouches isn’t rocket science, but it’s not something to wing either. With the right partner, smart planning, and a bit of print-savvy foresight, you can avoid the most common pitfalls and get packaging that actually does what it’s meant to do.
Whether it’s eco-friendly custom pouch packaging, short-run digital pouch printing, or scaling up with gravure, Aropack is here to help you bring your packaging vision to life, beautifully and efficiently.
Let’s make your next launch smart, scalable, and shelf-ready. Give us a call on 01233 281460 or send us an email at info@aropack.co.uk for a free consultation.