As a leading digital flexible packaging manufacturer in Orlando, SunDance provides flexible pouches to businesses across various industries. Flexible packaging is an ideal solution for a vast number of products, including food and beverages, pet food, natural and organic products, as well as sports and nutrition products. It is an excellent option for packaging items that require a moisture barrier to stay fresh or for products with unusual shapes that would benefit from flexible packaging.

Our flexible packaging services take care of everything, from package design and printing to production and shipment to your warehouse. We strive to ensure that all of our flexible packaging clients and their end consumers are completely satisfied with our services.

What Is Flexible Packaging?

As the name suggests, flexible packaging or “flex pack” is packaging made of flexible films and substrates. It has a certain amount of give and bend, making it useful for many different types of products. It’s often used for food, confectionery, and nutritional or organic products, but has a broad range of uses. Digital printing on flexible packaging gives you a high-quality finish for your products so that it’s ready to be sold, whether in stores or online, ensuring a professional look for your brand. It can be made in several different styles, including pouches that can be stood up or can lie flat.

Contact US

High-Quality Digital Printing

When you partner with SunDance for flexible packaging solutions, you get top-quality digital printing from our state-of-the-art, USA-based manufacturing facility. Our cutting-edge printing capabilities allow companies of all sizes to harness the power of our HP Indigo 25k digital press. Digital printing offers a number of other excellent benefits, too, in addition to the great quality images it produces. Our digital flexible packaging manufacturing capabilities allow brands to print multiple versions or SKUs of a product in one print run, while eliminating the need for plates. Our manufacturing methods also allow for lower minimums, shorter lead times, and less waste compared to conventional flexographic print methods, as well as superior high-definition print quality.

There’s no need to compromise on quality to get these brilliant advantages. Digital printing can deliver it all and is even better when paired with flexible packaging.

Benefits of Custom Digitally Printed Flexible Packaging

Custom digitally printed flexible packaging offers a wide range of advantages for modern brands—especially when speed, customization, and shelf impact matter. Compared to traditional packaging methods like rigid cartons, tins, or jars, flexible pouches and rollstock film provide an innovative solution that’s lighter, leaner, and more visually dynamic.

With digital printing on flexible packaging, SunDance empowers brands to take full control of their packaging production. Unlike traditional flexographic printing, which often requires high minimum order quantities and costly plates, digital printing enables:

• Low minimums – Perfect for small runs, seasonal products, new SKUs, and emerging brands
• Multiple SKUs in a single run – Produce product variations with ease without additional setup costs for matching pouch structures
• Variable data printing – Customize each pouch with unique barcodes, expiration dates, or promotional messaging

Flexible packaging also offers functional and logistical benefits that make it a preferred option across many industries:

• Lightweight and space-saving – Lower shipping costs and maximize shelf space
• Excellent product-to-package ratio – Reduces excess packaging waste and supports sustainability goals
• Extended shelf life – Barrier films can help preserve freshness and protect against moisture, oxygen, and light
• Enhanced visual appeal – Full-surface printing, high-resolution graphics, and tactile embellishments make your product stand out
• Durable and consumer-friendly – Easy to open, reseal, and store; ideal for on-the-go lifestyles

And because our flexible packaging is manufactured in-house using advanced HP Indigo digital presses, we’re able to deliver quick turnarounds and precise color, all with the high quality you’d expect from Florida’s Best Printer. Whether you’re switching from cans, cartons, or rigid containers, flexible packaging offers a modern, cost-effective solution that supports your marketing, branding, and operational goals.

Safe Packaging for Food

Our flexible packaging services are ideal for food and beverage products, as well as natural and organic products, and sports and nutritional product ranges too. We have experience with making food-safe packaging, so we know what it takes to ensure your packaging follows the rules for packaging consumable items. Flexible packaging offers a good option for all kinds of products, from confectionery to snacks ranging from jerky to healthy dried fruits and nuts. You can cut down on packaging by using flexible packaging instead of more rigid conventional packaging options, which often take up more space. Using less packaging makes your brand more sustainable and saves money in a variety of ways, including on storage and transport.

REQUEST QUOTE

Custom Printed Rollstock and Pouches for HFFS and VFFS

At SunDance, we specialize in manufacturing custom printed flexible pouches and rollstock film designed for compatibility with Horizontal Form-Fill-Seal (HFFS) and Vertical Form-Fill-Seal (VFFS) machines. Whether you’re working with a co-packer or operating your own automated packaging line, our flexible packaging solutions are optimized for efficient forming, filling, and sealing processes.

HFFS and VFFS refer to two primary types of automated packaging systems. HFFS machines are ideal for individually wrapped items such as nutrition bars, flat sachets, or wipes—products that are best filled and sealed while lying flat. VFFS machines, on the other hand, are vertically oriented and well-suited for loose, granulated, or powdered goods like trail mix, coffee, or snacks. Our high-quality rollstock films and preformed pouches run smoothly on both systems, ensuring reliable sealing, high-speed production, and a premium branded finish.

Whether you need digitally printed rollstock for high-performance packaging lines or custom pouches that are shelf-ready and eye-catching, SunDance delivers flexible packaging that’s ready to perform.

Stand-Up Pouches

Stand-Up Pouches, or SUPs, are an excellent way to package and protect your product, while displaying your brand’s message with full-coverage custom graphics. Stand-Up Pouches are often a great way to remove secondary packaging, like a retail carton, as this format can stand independently on the shelf, to save both resources and money!

Specialized Pouching Capabilities

At SunDance, our flexible pouch manufacturing process is built for customization at every level. From material selection to shape and finish, our specialized pouching capabilities allow you to create packaging that’s as unique as your product. Whether you’re looking for something sleek and simple or bold and unconventional, we can bring your vision to life with precision and quality.

Our pouches are fully customizable — including standard formats like stand-up, lay-flat, and gusseted styles — as well as custom die-cut shapes and sizes. With dual-web capabilities, you can mix and match different materials on the front, back, or gusset for both functional and aesthetic purposes. Whether you need a clear front to showcase your product, a metallized back for barrier protection, or matte finishes for a premium feel, we can tailor each component of the pouch to your specific needs. From start to finish, SunDance offers unmatched flexibility and control in pouch design, helping brands of all sizes stand out on the shelf while meeting practical performance requirements.

Find general information on our technical specifications listed below. While these outline our standard pouch size ranges and materials, we offer flexibility and can often accommodate custom requests—pending material compatibility and testing.

Templates & Dielines

At SunDance, we make it easy to kickstart your packaging project with a library of dielines and templates for the most popular pouch sizes and formats. These ready-to-use files are ideal for brands looking to move quickly and streamline the design-to-production process. Whether you’re producing a stand-up pouch, lay-flat pouch, or something in between, our standardized dielines are optimized for efficient setup and precision pouching.

Need something unique? No problem. Our in-house dieline engineers are experts at developing custom dielines tailored to your exact product dimensions, packaging goals, and machine requirements. From irregular shapes to hidden zippers, we’re here to help bring your creative vision to life.

SunDance’s Flexible Packaging Manufacturing

SunDance is an award-winning, G7® Master Certified commercial printer and packaging manufacturer based in Central Florida, proudly serving brands across the country with innovative, high-quality print and packaging solutions. As a leader in digitally printed flexible packaging, SunDance offers a full range of capabilities. From custom stand-up pouches and lay-flat sachets to rollstock films ready for HFFS and VFFS machines, our packaging is produced in-house allowing for faster turnarounds and exceptional attention to detail. With low minimums, variable data printing, and a commitment to sustainability, SunDance makes it easy to bring bold, retail-ready packaging to life. Contact our team today to start your next custom flexible packaging project and see how small changes can make a big impact.

Contact US