Potential advantages
Efficient high-speed packing; good for individually wrapped products; repeatable pack dimensions; strong branding across the web.
Flexible Packaging · Technical GuidePillow Packs & Flow Wrap
Pillow Packs & Flow Wrap
Explained.
A continuous web is formed around a product and sealed into a pack with a characteristic pillow-like shape. Flow wrapping commonly forms a film tube around a product, then closes a longitudinal fin or lap seal and transverse end seals. The pack shape follows the product and the machine setup. “Pillow pack” is a common description of the finished appearance, not a guarantee of one exact seal layout.
First, recognise the pack
What this format looks like
Flow-wrap packaging forms a flexible pillow-shaped pack with a longitudinal seam and end seals.
- Identify the overall silhouette before choosing the material.
- Check how the package stands, opens, fills and seals.
- Keep important text and logos clear of folds, fitments and seal zones.
The mock-up helps identify the pack silhouette; the technical section explains the seam and end-seal zones that affect artwork. This is a conceptual visual, not a production sample or approved dieline.
Schematic only; not to scale. Final material construction, dimensions, seals, closures and print zones must come from the selected packaging converter.
01 / Anatomy & construction
What is this format?
Flow wrapping commonly forms a film tube around a product, then closes a longitudinal fin or lap seal and transverse end seals. The pack shape follows the product and the machine setup. “Pillow pack” is a common description of the finished appearance, not a guarantee of one exact seal layout.
Key components
- Longitudinal seal
Runs along the pack length; may be a fin seal or lap seal depending on the machine and web. - End seals
Transverse seals close the ends and create the pack boundaries. - Cut-off position
Separates individual packs at a defined repeat and must avoid cutting important artwork. - Product window / print panel
Graphics must remain aligned after the film wraps around the product. - Registration mark if required
A machine-readable mark may control print-to-cut alignment; its position and colour must follow converter instructions.
Design principle: build the artwork around the real pack construction, not the other way around. Folds, seals, fitments and machine requirements can change the printable area.
02 / Materials & structure
What is it made from?
Common component roles are described below for learning. They are not a recommended bill of materials for every product or supplier.
| Component / layer | Typical role and specification questions |
|---|---|
| Printable outer web | Provides the graphics and the surface properties needed for handling and printing. |
| Optional barrier or support layer | Selected for product requirements and machine performance. |
| Sealant surface | Allows the film to form longitudinal and end seals under the process conditions. |
Important: a pack’s performance depends on the complete converted structure, including seams, folds, seals, fitments, thickness, process settings and storage conditions. Ask the converter for supporting technical data and product-specific validation.
03 / Applications & trade-offsPROTECTION PRODUCTION USE & DISTRIBUTION
Where is it used?
Biscuits, confectionery, bars, bakery products, soap, stationery, multipacks and individual items wrapped at speed.
Trade-offs to consider
Graphics can rotate around the product; end seals consume space; film tracking and registration affect print alignment; not normally reclosable.
Define the product’s sensitivity to moisture, oxygen, light, aroma, contamination, impact or leakage where relevant.
Confirm filling equipment, speed, sealing method, machine compatibility, pack orientation and expected production volume.
Consider transport, stacking, shelf presentation, opening, carrying, reclosure and local end-of-life realities.
04 / Artwork & prepress
Designing for the real pack
Design around the actual wrap path, fin-seal position, end-seal allowances and cut pitch. Confirm whether the print is viewed upright on the shelf or when the pack is held.
Pre-production checklist
- Obtain web width, cut-off/repeat and print direction.
- Mark fin seal, end seals, registration mark and cut lines.
- Keep product name and key graphics away from seal and cut zones.
- Confirm film orientation and surface/reverse printing.
- Run a machine trial or approved proof where alignment is critical.
Artwork handover: request the approved dieline or panel drawing, print specifications, colour guidance, technical layer instructions and proofing procedure from the supplier. Never assume a generic template is production-ready.
Read the full artwork & prepress guide ↗05 / Common questions
Frequently asked questions
Is flow wrap the same as a pillow pouch?
The terms overlap in everyday use, but flow wrap usually refers to the wrapping process and pillow pack to a common resulting shape.
Why can artwork appear shifted?
Film tracking, registration, pack rotation and the relationship between cut and seal zones all affect alignment.
Can flow wrap be used for food?
Yes, when the complete structure, inks/adhesives where relevant, sealing process and food-contact compliance are suitable for the intended use.
This guide is educational and is not a substitute for packaging engineering, product testing, food-contact review or current regulatory advice. Confirm applicable Kenyan and destination-market requirements with the responsible product owner and qualified specialists.
Need packaging artwork for this format?
Share the product, target pack size, filling method, reference images and converter specification. Briandcas can help scope the design and prepress requirements.