Case Study: Custom 3D Side Gusseted Pouch with Precision-Fit Spout
The Challenge
An engineering firm was developing a specialized liquid containment system for their own customer and needed a flexible inner package that could integrate precisely with a rigid outer container. After evaluating available options, they determined that no off-the-shelf packaging could meet the dimensional, functional, and performance requirements of the system.
The project presented several technical challenges:
Designing a side gusseted pouch that would cube out consistently to fit within a rigid housing
Integrating a spout that aligned exactly with the outer container connection
Holding tight dimensional tolerances required for assembly and system performance
Developing a fully custom solution with no existing market equivalent
The Solution
Heritage Packaging worked closely with the engineering team to design a custom 3D side gusseted pouch built to exact specifications. The pouch structure was engineered to cube out reliably, ensuring consistent geometry and stability when placed inside the rigid outer container.
A precision-fit spout was incorporated into the pouch, with placement and sealing controlled to align accurately with the external container interface. Achieving this required careful coordination between pouch construction, spout selection, and installation processes.
Every aspect of the package was developed specifically for this application, from material selection to pouch dimensions and spout positioning. Very few flexible packaging manufacturers have the in-house capability to design and produce a side gusseted 3D pouch that cubes out consistently while maintaining the tight tolerances required for precision spout alignment within a rigid outer container.
The Result
A fully custom 3D side gusseted pouch that cubes out consistently
A precision-installed spout designed to interface seamlessly with a rigid outer container
A packaging solution that enabled the customer to move forward where no standard option existed
A repeatable design ready to scale as the system advances
Why It Matters
In complex engineered systems, packaging often functions as a critical component rather than a passive container. This project demonstrates how custom flexible packaging can support system-level performance when standard solutions fall short.
By collaborating early in the design process and manufacturing to exact specifications, Heritage Packaging helped turn a packaging limitation into a workable, production-ready solution.
Looking for a Custom Packaging Solution?
If your application requires a flexible packaging solution that does not exist off the shelf, Heritage Packaging specializes in designing and manufacturing custom packaging built to meet precise performance and dimensional requirements. Contact our team to start a conversation.
Certain project details have been intentionally omitted to respect customer confidentiality.