Archive: Nov 2022

Why Is Flexible Packaging Replacing Can Packaging?

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Flexible Packaging Replacing Can PackagingThe flexible packaging market continues to grow and is expected to increase from an estimated $68.5 billion in 2021 to $102.8 billion by 2031, according to a report by Allied Market Research, with a compound annual growth rate (CAGR) of 4.2%. There is a reason why flexible packaging is increasing and replacing rigid types of packaging materials, although making the switch in packaging formats can seem daunting. Of this increase in flexible packaging, retort pouches, in particular, are expected to experience the highest growth rate due to growing end-user demand.

There are several reasons why  flexible packaging replacing aluminum cans across a broad range of industries, such as food products, consumer goods, electronics, and cosmetics. Flexible packaging increases marketability and adds value to both food and non-food products, providing protective packaging properties with durable, flexible materials, including films, plastics, foils, and paper.

Some of the most important reasons that are driving the change from cans to flexible packaging include:

  • Sustainability
  • Advancements in flexible film technology
  • Flexibility, versatility, and customizable
  • Protects shelf-stable products
  • BPA free
  • Safety


Sustainability is a big plus for flexible packaging and one of the largest reasons for the increase in companies making the switch from rigid to flex packaging materials. Flex packaging provides a sustainable alternative with a comparable shelf life as cans yet can save up to 75% of material costs. Flex packaging requires considerably fewer materials, less fuel for production and transportation, and takes up less waste in landfills, although it is typically completely recyclable.

Flex packaging provides a green solution to the packaging industry, increases a company’s reputation for showing corporate responsibility, and significantly reduces the carbon footprint related to packaging. Sustainability is at the top of the list for the advantages of flexible packaging.

Advancements in Flexible Film Technology

Significant breakthroughs in flexible film packaging technology have improved the durability and resilience of flexible packages with high barrier protection and resistance to water, air, or spoilage.

Flexible Packaging Is Versatile and Customizable

Flexible packaging is highly versatile and customizable, with a variety of materials available in just about any size required. This significantly reduces extra space required for shipping and storing, as flexible packaging adjusts to the contours of the products to optimize space. Flexible packaging can include printing, stickers, tamper-resistant seals, and a variety of customizable designs and features.

Flex Packaging Protects Shelf Stable Products

High-barrier flexible packaging films are strong and durable enough to store shelf-stable food products without requiring refrigeration or freezing. These products in the past were stored in rigid containers for long-lasting protection.

Most Flexible Packaging is BPA Free

Bisphenol A, BPA, is a chemical that is commonly found in food packaging made of epoxy resins and polycarbonate plastics. BPA is found in polycarbonate plastics in beverage containers such as water bottles and in epoxy resins which are used to line the interior of metal food cans and bottle tops. According to the Mayo Clinic, some research shows that BPA can seep into food and beverages from storage containers and cause possible adverse health effects.
The FDA, however, has determined BPA is safe at very low levels. You can reduce your exposure to BPA by using BPA-free packaging products such as the many types of flexible packaging options.

Safety of Flexible Packaging

gone are the days of requiring employees to open large metal cans to expose a lid with very sharp edges. Safely handling and disposing of food and beverage containers is always a concern for food service operators. Grocery stores, restaurants, and food supply chains can lessen the risk to their employees for on-the-job injuries and cuts, which may cause Workmen’s Comp. claims and create blood-borne pathogen contamination issues as well. Flexible pouches designed with friendlier open and close features like tear notches and slide-to-close features significantly help to reduce injury rates in the food service industry and speed operations with easy open access.

Peoria Production Solutions, PPS, can help you realize the many benefits of flexible packaging as an experienced contract packaging and flex packaging provider. We provide high-quality flex packaging, auto bagging, heat sealing, auto labeling, and more with modern equipment and a highly trained staff. Contact us to learn more and realize the benefits of switching from rigid cans to flexible packaging.

Outsourcing EV Cable Assembly

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Cable AssemblyElectric Vehicles (EVs) continue to be a growing industry and topic of discussion, especially as gas prices only go up and eco-friendly solutions are mandated due to climate change. EV cable harnesses have many components that require precision assembly.

Some stripping and crimping of cables can be done with automated equipment, while other tasks require manual work and assembly. Working with high-voltage connectors requires specific work processes to be performed in order. Automated processes cannot be used for every task, and some manual requirements are more complex than others.

Benefits of Outsourcing EV Cable Assembly

Some EV cable types require a certain set of processing steps, while others require different steps to be followed. In some cases, it could make sense for the manufacturer to automate critical steps and outsource other processes, such as assembly. There are many benefits to outsourcing various aspects of EV assembly requirements. A manufacturer’s decision to outsource is dependent upon various factors, and evaluation of the potential benefits will help to decide the best way to meet manufacturing goals.

Reduces Labor Expenses

One of the biggest advantages of outsourcing electric assembly processes is the reduction of labor expenses, which is not just limited to wages. Companies can avoid the need to hire staff, invest in training, and provide benefits, taxes, and insurance. Outsourcing also allows companies to meet their production and shipping demands without worrying about maintaining the proper staff levels throughout the year, even with fluctuations in production requirements.

A contract electronics kitting provider will be there when you need them, and you don’t pay for their services when they are not needed. This helps reduce labor costs and helps companies to grow by focusing on their most important needs without worrying about staff levels for electronic kitting and assembly projects.

Improved Efficiencies

EV producers are continually investing in research and development and product improvement. Outsourcing electronic assembly processes allow companies to focus on improved manufacturing techniques and efficient production. By outsourcing electronic assembly services, companies can rely on their contract assembly provider without the need to invest in automated equipment and workstations optimized for the efficient flow of goods.

Changes in Production Demand Are Met Quickly

When production demands change quickly, an outsourced provider is always ready without the need to invest in new staff, training, and capacity for increased production and assembly requirements.

Experienced Electronics Kitting Services

Peoria Production Solutions, PPS, is an industry-leading contract electronics kitting services provider with more than 80 years of experience in helping companies to meet production goals. We offer custom kitting and assembly, including contract electronic kit assembly, electronics kitting services, sub-assembly, final assembly, single or multi-step assembly, and assembly of various mechanical and electrical components.

PPS provides peace of mind to companies that require careful electronic kitting and assembly with a track record of satisfied customers. We substantially invest in our employee training and development programs with a focus on meticulous attention to detail. PPS offers automated equipment, a large, modern facility, and a staff dedicated to a job well done and total customer satisfaction.

PPS differs from other contract electronic assembly providers with our not-for-profit status, allowing us the flexibility to provide solutions that other assembly providers cannot. We utilize automated equipment combined with a skilled and trained workforce to deliver quality assembled products, on time. Contact us with any questions and for cost-efficient, high-quality solutions for your next electronic kit and assembly requirements.

Tips on Reducing Packaging Costs

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Packaging CostsCompanies in all industries are feeling the squeeze of price increases and supply chain issues. The value of a dollar does not go as far as it used to, and companies are evaluating every aspect of operations to find opportunities for cost savings. No matter what business you’re in, one thing typically remains constant, and that is that all companies need some form of packaging.

Packaging Is a Constant, Critical Process for All Businesses

Packaging might be one of those elements that are taken for granted, performed the same way it’s always been done. Most businesses are busy manufacturing or promoting their niche products and forget to evaluate their packaging process periodically. Many companies continue to purchase the same types of corrugated boxes in the same sizes from the same supplier and perform in-house packaging the same way.

This consistent demand for packaging should not be overlooked and is one of the best places to start when evaluating your processes and supply chain for cost savings.

Make Smarter Packaging Choices

Instead of evaluating your packaging process only to cut costs, business managers should focus on making smarter packaging choices. Packaging always has to meet the most important demands, such as product protection, brand awareness, and traceability. Not all packaging expenses are tied up in material, evaluating the entire process is critical to recognizing areas for improvement.

Some things to do to make smarter packaging choices include:

  • Be proactive – don’t wait until you experience skyrocketing costs for your supplies.
  • Identify all packaging cost factors – evaluate all cost factors, including material, delivery times, shipping costs, labor, and capacity.
  • Analyze packaging inventory – make sure your packaging fits your products without excessive need for dunnage. Consider using padded envelopes instead of boxes when possible.
  • Use the right size of boxes – most carriers like UPS and FedEx base pricing now on dimensions in addition to weight. Using oversized boxes is a waste of space and money.
  • Evaluate internal packaging processes – is your packaging process optimized for efficiency? Streamlining work processes with an organized flow of materials, without backtracking over workstations to get your products from production, to packaging and shipping, can reduce workspace, free up capacity, and cut costs.
  • Consider outsourcing packaging – evaluating contract packaging companies, and ask for assistance in evaluating your total packaging costs compared to your current expenses. In the past, companies may have considered contract packaging unaffordable, although contract packagers today are a valuable addition to many supply chains.

Contract Packaging Provides Many Benefits

Working with a contract packaging company provides many benefits over companies performing packaging in-house. Contract packagers offer expertise in the various types of packaging materials and can make suggestions for types and sizes of boxes and other packaging materials that can meet a company’s needs while providing cost savings.

One of the greatest advantages of working with a contract packaging company is the ability to free up floor space at current facilities. Shipping product in bulk to a contract packager allows companies to focus on their niche product production and receive their products back ready for direct shipment or sale. This saves on internal packaging labor and allows companies to grow with an expert packager fulfilling this very important role.

PPS Offers Quality Contract Packaging Services

Peoria Production Solutions, PPS, offers a wide range of quality contract packaging services for all types of companies.  PPS is an expert Midwest contract packaging company with more than 80 years of experience in helping companies to meet production goals. Our contract packaging services include primary and secondary packaging, repackaging, packing, kitting, assembly, auto bag filling, cello wrap, and flexible packaging and palletizing services.  We also provide electronics kitting and government sewing contract services. 

PPS is a fully sustainable, not-for-profit contract packaging company focused on total customer satisfaction through employee development and training. We follow strict quality policies as part of our :

Peoria Production Solutions, PPS, offers a wide range of quality contract packaging services for all types of companies.  PPS is an expert Midwest contract packaging company with more than 80 years of experience in helping companies to meet production goals. Our contract packaging services include primary and secondary packaging, repackaging, packing, kitting, assembly, auto bag filling, cello wrap, and flexible packaging and palletizing services.  We also provide electronics kitting and government sewing contract services. 

PPS is a fully sustainable, not-for-profit contract packaging company focused on total customer satisfaction through employee development and training. We follow strict quality policies as part of our ISO9001:2015 registration and provide full material traceability with our ERP system. Contact us to learn more about how our contract packaging services can provide you with packaging cost savings.

Quick Guide: Secondary Packaging for Cosmetic Products

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 Secondary Packaging for Cosmetic Products

The cosmetics industry is one where secondary packaging plays a primary role in brand identification and differentiation, in addition to product protection. The packaging used for cosmetics provides an excellent opportunity for marketing and increasing brand awareness. To understand the importance of secondary packaging in the cosmetics industry, it is important to understand the difference between primary and secondary packaging and the roles they play.

Primary and Secondary Packaging in Cosmetics

Primary packaging is what actually holds the product and comes in many forms, such as the plastic tube that holds mascara, glass jars that hold nail polish, or spray bottles for perfume. Primary packaging typically displays important product information such as ingredients, expiration dates, usage instructions, and more.

Secondary packaging is the outer packaging that keeps products safe and protected during storage, handling, and shipping. Secondary packaging also plays a critical role in the cosmetics industry as the primary container that holds the tube of mascara or lipstick and contains important information such as brand colors, logos, products, and company information. In many cases, secondary packaging for cosmetics does more than protecting products, it drives sales with eye-catching designs and messages.

Tips for Designing Secondary Cosmetic Packaging

We have all seen the boxes of toothpaste that claim to whiten teeth or makeup and nail polish with a sample swatch of color on the outside of the packaging. These tactics used in secondary cosmetic packaging are meant to attract consumers with vibrant colors and important messaging. Some of the most important tips when designing secondary packaging for the cosmetics industry include:

  • Organic, Earth-Friendly Color Palettes
    Organic colors that resemble nature are common in the cosmetics, health, and beauty industry as they resemble youth, life, and vigor. Earth-friendly colors such as greens and blues can also add a comforting and warm feel to your cosmetic packaging.
  • Eye Catching Patterns
    You’ll see eye-catching patterns all over cosmetic packages. Vibrant colors with strong fonts and well-placed design elements give cosmetic packaging the differentiation they need from other products. Abstract patterns make cosmetics stand out all those should still be designed with colors and fonts that are pleasing to the eye.
  • Using The Right Typography
    It is important to choose the right fonts for your brand, one that goes well with your design elements and resonates with your target customers. The right typography is especially important in minimalist designs where the brand name is the main focus.
  • Foil Stamping Adds a Premium Effect
    Foil stamping in silver, copper, or gold adds a premium accent to cosmetic packaging, enhancing visual impact with an upscale, luxurious look.
  • Include Images
    Incorporating images is another way to make secondary cosmetic packaging more interesting. Images can cover an empty background or be combined with illustrations and other design elements.
  • Inside the Box Printing And/or Patterns
    Don’t forget about what your consumer sees when they open the box. Well-placed patterns and prints inside the box can further enhance a consumer’s pleasant feeling when unwrapping cosmetic products.

These are some tips to improve secondary cosmetic packaging, which is often the first thing to catch the consumer’s eye, even though it is also the first to be tossed after opening. Using tried-and-true techniques for cosmetics secondary packaging helps companies get the most bang for their buck for this important yet disposable type of packaging.

Working with an experienced contract packaging company can help companies to understand their options for types of secondary packaging available, costs, and labor expenses.

Peoria Production Solutions, PPS, is an experienced contract packaging provider with more than 80 years of expertise in providing various types of packaging services. We offer flex packaging, auto bagging, kitting and assembly, and many other services, including secondary packaging. Contact us to learn more about improving your packaging process by outsourcing to an experienced, cost-efficient and quality-minded secondary packaging provider.

Auto Poly Bagging Fastener Kits

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Poly Bagging Fastener Kits


Auto bagging hardware pieces like fasteners, nuts, and bolts, with other necessary materials, is a popular custom kitting technique. Polybagging fastener kits saves time for field personnel to have the right parts ready when needed or provides a convenient package for the end-user. 

Fastener Kits Save Time with Convenience

Fastener kits put together for specific tasks such as assembling furniture or for specific repairs such as computer repairs or kits containing skateboard hardware, for example, give the buyer everything they need in one convenient, protected pouch. Polybagging hardware and fastener kits is also a common practice during manufacturing processes where operators require specific parts during their assembly application. Fastener kits can be provided along with products during a manufacturing process and sometimes sold on their own for specific processes, such as a picture hanging kit. 

Designing Custom Poly Bagging Fastener Kits

Auto poly bagging processes are used in many applications for retail, commercial, and industrial applications to protect specific merchandise required for production, shipping, or sale. Identification tags can be attached to poly bags to indicate the number of products included, with barcode labels for tracking purposes. This one SKU can replace the numerous individual SKUs of all parts included, improving inventory movement applications. 

Designing a poly bagging process requires careful consideration of a few important factors:

  • The specific products included in the bag
  • The number of products to be auto bagged
  • The type of poly bag or pouch most beneficial for packaging

Determining the exact products to be included is one of the most obvious important decisions to make when designing an auto-bagging process. Fasteners can be included with other required hardware or products, such as plastic parts or adhesives. Printed materials can also be included, such as an inventory list of kit contents and assembly instructions.

The quantity of custom poly bagged products is a critical decision to ensure all required parts are included in possibly a couple of extra fasteners or nuts and bolts if some get lost or damaged. Companies also must ensure they have adequate inventory to maintain custom bagging processes to support product ordering and sales.

The type of packaging is another critical decision, as there are several different types of poly bags available in different sizes, shapes, weights, and thicknesses.  The type of packaging chosen should protect the parts inside for proper bagging and sealing, with the most efficient material available without jeopardizing product or process quality. 

Types of Poly Bags for Custom Auto Bagging and Kitting

There are several types of poly bags available for custom auto-bagging processes, which requires careful consideration of certain factors to choose the best type. Companies will want to consider the size of the bag required, the bag’s physical characteristics, and costs. Some bags will be visible to consumers, others will simply be used for protective packaging during shipping. 

The most common types of poly bags include polyethylene and polypropylene types of bags, with many different variations of polyethylene density.

High-density polyethylene, HDPE – HDPE bags are less flexible and denser than other types of polyethylene bags providing excellent resistance to tears and punctures. HDPE bags are often used to package heavy items such as construction material, sand, and cement, but can also be useful for packaging bulk food items and irregularly shaped products with sharp edges that could poke a hole in other types of bags.

Low-density polyethylene, LDPE – LDPE bags are less dense than HDPE bags providing more flexibility and clarity to see products on the inside. LDPE bags tear easier than other types of bags, which is convenient for products that require easy access, lightweight, and have visibility, such as for small parts or temporary storage.

Linear low-density polyethylene, LLDPE – LLDPE bags provide higher tensile strength and puncture resistance than LDPE bags without jeopardizing flexibility.  LLDPE bags can save money with thinner gauge material and still provide strength, making them common for grocery store use, where clarity is not an issue. 

Medium-density polyethylene, MDPE – MDPE is not quite as dense as HDPE, although it still provides heavy-duty properties with resistance to stress and cracking. MDPE bags are useful to protect against external damage, debris, and moisture. 

Polypropylene, PP – PP bags are the second most common type of bags used compared to polyethylene bags and are growing in popularity due to high tensile strength and clear visibility. Polypropylene provides increased resistance to heat and chemicals over polyethylene. 

These are some of the most common types of bags used for auto-bagging processes, although consulting with an experienced custom kitting and auto bagging provider will help you determine the right type of materials for your process.

Peoria Production Solutions, PPS, offers more than 80 years of experience as a contract packaging provider, offering all types of packaging services, including auto bagging. We utilize modern auto bagging equipment, heat sealers, heat tunnels, band sealers, hot stamp imprinters, and other auto bagging technology combined with a skilled, trained staff. Contact us to learn how to improve your poly bagging application with an experienced, quality-minded auto bagging provider. 

Custom Kit Assembly & Gift Set Packaging Provider

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Custom kit assembly is the process of combining two or more individual products into one assembled kit with one single SKU. Custom kitting and gift set packaging are ideal for companies to prepare similar items for retail sales. Kitting can improve packaging and shipping time and reduce overall expenses.

Common Gift Set and Custom Kit Assembly Products

Custom kitting can be used in a wide range of markets to fulfill many types of orders. Some of the most common types of products that are commonly grouped together for custom kitting or gift set packaging include cosmetic kits, skincare kits, toys, entertainment media, product samples, and many other types of items.

Oftentimes, purchasing kitted items is a better value than buying items individually. This is a good way for companies to boost their sales while still providing cost savings to consumers.

Cosmetic Kits

Cosmetics are commonly packaged with like items that appeal to consumers, such as eyeshadows, mascara, and eyeliner grouped together for a complete eye makeup kit. Shades of eye shadows and blush colors that go together or foundations and powders in the same color scheme are commonly kitted for consumer convenience. Cosmetic companies often introduce new products in a custom kit and may offer more promotional items in gift sets during the holidays.

Skincare Product Kits

Skincare products are also commonly kitted together with facial cleansers, moisturizers, and toners that work together to provide a full skincare regimen. Skincare items can be grouped together based on skin types, such as dry skin or oily skin. Kitting is a very popular sales approach for many companies in the skincare industry to help keep costs down and cater to consumer needs.


Custom kitting and gift set packaging has been a common practice in the toy industry for a wide variety of toys such as model cars and airplanes, Lego kits, Barbie dolls and clothing accessories, Nerf guns, coloring books with stickers or other activities, outdoor games, and more. Toys, games, and hobby kits grouped together provide cost savings for the manufacturer and convenience for consumers.

Entertainment and Media Kits

The entertainment industry is another popular market for kitting, or companies can offer discounts for purchasing a series of movies or books that go together. Media systems like sound bars and speakers, televisions and mounting brackets, or car stereos and speakers are other options for kitting that can improve company sales and provide savings to buyers.

New Product Samples

Kitting services are a popular way for companies to promote new products, and offering product sample kits gives customers a chance to try the product out before buying a full-size version. Companies in all types of industries promote new products with kitting for a cost-effective way to increase brand awareness. A sampling of several types of products is often quite appealing to consumers, such as a variety of lotions or perfumes.

Gift Set Packaging

Gift set packaging is extremely popular around the holidays with everything from cosmetics, pajama sets, tool sets, cooking ware, holiday decorations and more packaged in a convenient gift set. Gift set packaging is not just for the holidays, however, with clothing and personal care items often available in gift sets for convenient bundling or gift-giving any time of the year.

With the many opportunities for kitting and gift set packaging, companies need a contract packager with experience in kitting and assembly to help them navigate the many options.

Kitting, Assembly, and Gift Set Packager

Peoria Production Solutions, PPS, has been providing contract packaging services for more than 80 years and offers extensive experience in all types of kitting and assembly. PPS is an industry-leading Midwest kitting and assembly provider, offering secondary production solutions, including packaging, repackaging, and gift set packaging.

PPS offers secondary production solutions to a wide range of businesses and industries, helping some of the largest Fortune 100 companies meet their production goals. We offer the resources, staff, and capacity to dedicate kitting and assembly lines for your process, with a controlled flow of goods, ERP product traceability, and ISO9001:2015 quality policies. Contact us to learn more about improving your kitting, assembly, and gift set packaging process.