1 L Retort Spout Pouches Replacing Rigid Bottles for an Australian Juice Producer
Reducing packaging weight by ~85% while keeping hot-fill safety and shelf stability.
A cold-pressed juice producer wanted to cut shipping weight and shelf space for their 500 ml and 1 L juice range. We supplied 1 L retort spout pouches in a PET/NY/PE structure with 32 mm screw caps, hot-fill rated and validated with a 72-hour leakage test on the spout weld.
The Challenge
What the brand was up against
Before switching, the client faced several technical and commercial issues that the previous supplier could not solve.
- Glass and rigid PET bottles were driving shipping cost and shelf footprint.
- Hot-fill and pasteurisation were required — pouches had to survive high temperatures.
- Retail buyers needed a leak-proof spout that could withstand repeated opening.
- Brand identity had to survive the switch from a bottle silhouette to a pouch.
Our Solution
What we designed and delivered
Every step was handled in-house — design, engraving, printing, lamination and bag making.
- Supplied 1 L and 500 ml spout pouches in retort-grade PET/NY/PE.
- Used 32 mm screw caps rated for hot-fill and retort processes.
- Ran a 72-hour leakage test on the spout weld before approving mass production.
- Shaped pouch silhouette kept the brand's visual identity on shelf.
Technical Specifications
Structure & production details
| Format | Shaped spout pouch with 32 mm cap |
|---|---|
| Structure | PET/NY/PE, retort grade |
| Closure | 32 mm screw cap, tamper-evident ring |
| Sizes | 500 ml / 1 L |
| Printing | 9-colour rotogravure, gloss finish |
| Volume | 2 SKUs, 400,000 pcs per year |
The Results
What changed after the switch
~85%
Packaging weight reduction
72 h
Leak test passed
2 SKUs
Range migrated
↓ 60%
Shipping cost per litre
Sampling was fast — digital proof in 24 hours, physical pouches in a week. The spout pouches replaced our glass bottles and cut shipping weight dramatically. Communication was clear throughout.
Have a Similar Challenge?
Tell us what you are packing, what shelf life you need and how your line fills. We'll propose a structure and send samples.