Conventionally, ghee (i.e. clarified butter) has been marketed in poly-pouched pillow packs, cartons or tin cans. These types of packaging are not user-friendly and are losing in the modern retail arena. Poly pouches are surface printed and pose a chronic problem with ink smearing during handling in the supply chain. The strength and barrier properties of the poly pouch structure itself are poor, let alone the machinability of the laminate/pouch on the filling lines. End users often find it difficult to retrieve the product packed in poly-pouched pillow packs, cartons and tins.

Noting these problems, Uflex Limited has recently launched a Profile Pouch for liquids with a sonically-sealed spout. It also offered the solution to Paras Dairy for packing its ghee. The laminate of the pouch, which is engineered at Uflex’s packaging plant at Noida, is a 3-ply structure comprising isotropic PET/isotropic PET/co-ex nylon polyethylene (PE). Two transparent isotropic polyester layers provide excellent mechanicals to the laminate that are required to withstand harsh supply chain conditions. Co-ex nylon PE is considered to be one of the finest sealant layers, imparting superior mechanical strength to the laminate in terms of elongation and impact resistance, and also preventing pin-holes and cracks in the final laminate structure. The Profile Pouch also conforms with the ASTM International Standards for measuring the damage resistance of a fibre-reinforced polymer matrix composite to a drop-weight impact event.

Furthermore, the 3-ply structure has been especially engineered to optimize the OTR and WVTR for extending the shelf life of the product packed. The designed OTR for the ghee pouch is less than 60 cm3/m2/day under 0 percent relative humidity (RH) at 23 degrees Celsius, while the WVTR is less than 5 gm/m2/day under 90 percent (RH) at 37.8 degrees Celsius. The conventional poly-pouched pillow packs do not provide adequate barrier protection from oxygen, thereby making the packed ghee vulnerable to drastic taste change.

Another major differentiator of this pack lies in its dispensing mechanism. Conventionally, spouts are heat-seal welded to the pouches, often resulting in leakage and polymer degeneration. In this case, high-frequency sound waves are generated and passed between the spout surface and the laminate. These waves vibrate the molecules of both PE layers of the laminate and that of the spout surface, enabling a strong leak-proof seal.

The laminate is reverse printed in high definition rotogravure, eliminating the possibility of ink smearing or bleeding. This renders a high finish to the spout pouch with visually stimulating and outstanding aesthetics. A specially designed bottom gusset allows the pouch to stand up on the retail shelf to enhance its visibility.

To impart infallible brand protection, a Uflex-unique 3D holographic stamp is sandwiched between the two transparent isotropic polyester layers. The holographic stamp is not susceptible to rupture by scratching or rough handling in the supply chain.

Keeping in mind the pouch integrity and functional ease for the end users, Uflex has fitted a tamper-locked spout to the pack. The cap is interlocked with the shoulder of the spout and this lock is broken when the cap is opened for the first time, ensuring an absolutely tamper-proof pouch. The spout has been internally designed to ensure that the entire product is easily accessed by gently squeezing the pouch. This profile pouch has hourglass contours that further facilitate a firm and handy grip for easy handling and pouring of the packed product.