Custom Printed Spout Pouches for Sauces, Purees and Refills

What is a spout pouch and where does the spout sit?

A spout pouch is a stand up pouch with a plastic spout welded into the top seal. A screw cap closes the spout, so the customer pours a little, caps it and puts the pack back in the cupboard or fridge.

The body is a laminate with a bottom gusset. Filled, it stands on the shelf like a small bottle. Empty, it folds flat, which is the main reason brands move across from rigid packs.

The spout can sit in the centre of the top seal or in one corner. A centre spout pours straight down and suits drinks and purees. A corner spout angles the neck, which makes pouring into a bottle or a pan cleaner.

Which products are sold in spout pouches?

Anything that pours or squeezes. UK sauce makers took to this format early, and bath and body refill brands followed because a pouch uses far less material than a bottle.

Our spout and retort pouch range groups the spouted styles beside the heat-processed pouches used for wet meals, so you can compare them on one page.

• Ketchup, hot sauce and barbecue sauce in squeeze sizes
• Fruit purees and smoothie pouches for young children
• Honey, syrup and fruit coulis for cafes and bakeries
• Hand wash, shampoo and body wash refills
• Cleaning concentrates and laundry refills
• Cold brew concentrate and juice shots

What size spout pouch holds 250 ml of sauce?

A 250 ml sauce pouch is often around 110 × 180 mm with a 60 mm gusset. That leaves headspace above the fill line, so the pouch can be squeezed without product rising up the neck.

Capacity comes from three numbers: width, height and gusset depth. Thick products need more headspace than thin ones because the filler leaves air behind in the pouch.

Describe the viscosity in plain words, such as runs like single cream or holds its shape on a spoon. We size the pouch and the spout from that, and our stand up pouch size guide shows the dimensions behind each fill.

Which laminate keeps liquids fresh?

Liquids work on a pouch from the inside. Acidic sauces and essential oils stress the seal layer, and oxygen passing through the film dulls colour and flavour over the months on shelf.

For long-life sauces and juices, PET / foil / PE blocks light and oxygen. Where a customer needs to see the product, clear PET / PE shows the colour and accepts a shorter shelf life.

Food-contact, high-barrier and compostable film options are available on request. Tell us the acidity, whether the product is hot-filled and the shelf life you want, and we match the structure, as explained in our guide to barrier films and laminates.

Caps, spouts and tamper bands

The fitting decides how the pouch is used at the table or in the bathroom. These are the common choices.

Printing around the spout

The spout is welded into the top seal, so the top 20 to 25 mm of the front panel is seal area and does not carry print. Keep the logo and product name below that line.

Full colour digital print handles photographic fruit and glossy sauce shots well. On foil, a white under-print goes down first so your colours do not pick up a metallic cast.

Our designers set your artwork on the dieline and send a free proof before anything is printed. The artwork guide for printed pouches lists bleed, seal areas and the files we need.

How do you fill spout pouches?

Most small brands fill through the spout with a hand or semi-automatic filler, then screw on the cap. Larger lines fill through an open top and seal it afterwards. Either way, the routine is the same.

1. Check the empty pouch stands with the gusset fully opened.
2. Fill through the spout to the agreed line, leaving headspace.
3. Wipe the neck so product does not sit under the cap thread.
4. Screw the cap to the stop; a tamper band should click once.
5. Squeeze the body gently and watch the spout weld for weeps.
6. Stand filled pouches upright in the case, never laid flat.

Common mistakes with spout pouches

Choosing a neck too narrow for the product is the usual one. Chunky relish blocks an 8 mm neck, and the customer squeezes until the seal gives way.

The second is ignoring headspace. A pouch filled to the brim cannot be squeezed without product shooting up the neck when the cap comes off.

The third is running a dark design right up to the spout weld. The weld area crinkles, and dark ink shows every crease. A lighter band around the spout hides it.

Spout pouches for bath and body refills

Hand wash, body wash and shampoo brands sell refill pouches so customers keep the bottle and buy the liquid again. A corner spout pours into a narrow bottle neck without a funnel.

A 500 ml refill pouch is often around 150 × 230 mm with an 80 mm gusset. A matte finish and a frosted window suit the clean look most of these brands want.

Scrubs and salts are dry and want a zipper instead of a spout. Those sit on our bath salt and scrub pouches page.

How to order printed spout pouches

Send the fill volume, what goes in, how you will fill it and roughly how many you need. Quantities are quoted per order, from £0.25 per unit, and the written quote confirms the figure.

You get a free design proof first. Once you approve it, production takes 4–6 business days, and delivery is free and tracked across the UK in 2–3 business days.

Misprinted or damaged pouches reported within 10 days with photos are reprinted or refunded. Start on the spout pouch quote request form or message us on WhatsApp.