Custom Spout Pouch Case Study
200,000 Custom Spout Pouches for a South African Beverage Project
This custom spout pouch case study follows a South African beverage project requiring a carefully controlled internal release function. Runlong Pack worked directly with the customer through in-person factory visits, technical discussions, sampling and production coordination in 2024 and 2025.
The client identity, finished product artwork and certain structural details are intentionally withheld at the customer’s request.
Project Overview
Custom Spout Pouch Case Study: A Functional Mixing Concept
This custom spout pouch case study involved more than a conventional printed pouch. The customer required a custom-shaped package designed around two separate contents that would remain separated until the consumer intentionally activated the mixing function.
200,000 Custom-Shaped Spout Pouches
Runlong Pack worked with a South African beverage customer on a custom spout pouch project requiring both a distinctive pouch shape and a controlled internal release function. The final production order was for 200,000 pouches, with project details reviewed through direct technical discussions and in-person visits in China.
Two Contents, Mixed Only When the Consumer Is Ready
The pouch concept was designed to keep liquid and beverage powder separated inside the package. When the consumer is ready to drink, deliberate pressure is applied to activate the internal release area so the two contents can mix inside the pouch.
Finding the Right Balance for the Internal Release
The key challenge was not simply creating an internal separation area. Its opening performance had to be carefully balanced so it could remain secure during normal handling while still responding when the consumer intentionally squeezed the pouch.
The internal release area needed to remain intact during ordinary handling and transportation before use.
The consumer still needed to be able to intentionally activate the mixing function by squeezing the pouch.
The project required close attention to internal seal behavior during sampling, adjustment and production preparation.
To protect the customer’s confidential product design, Runlong Pack does not publish the finished artwork, proprietary pouch construction details, internal geometry or specific production parameters associated with this project.
In-Person Collaboration
From First Factory Visit to Production Follow-Up
This project developed through direct communication and two in-person visits to Runlong Pack in Shantou. The first visit in 2024 helped establish the working relationship, while the customer returned in 2025 after placing the order to continue detailed project coordination.
2024 — First Meeting in Shantou
The customer originally travelled to China in 2024 while sourcing packaging machinery in Foshan. During the trip, Runlong Pack invited the customer to visit our facility in Shantou for an in-person introduction and packaging discussion.
- Customer travelled to China for packaging machinery sourcing.
- Runlong Pack arranged a visit to our Shantou facility.
- Initial pouch requirements and project expectations were discussed face to face.
- The visit helped establish direct communication and project trust.
2025 — Returning After the Order
After the custom pouch order was placed, the customer returned to China in 2025 and visited Runlong Pack again. This second visit focused on project follow-up and detailed discussion around the pouch specifications and functional requirements.
- The production order had already been placed.
- Project details were reviewed directly with the customer.
- Functional pouch requirements received particular attention.
- In-person communication supported continued coordination before production.
The relationship developed from an initial factory visit in 2024 into a confirmed custom spout pouch order and continued face-to-face project coordination in 2025.
Runlong Pack’s Approach
Fine-Tuning the Pouch Through Sampling and Functional Testing
The project required more than confirming pouch dimensions and artwork. Runlong Pack used repeated sampling, sealing adjustments and functional checks to improve the balance between transport security and intentional consumer activation.
Initial Sampling
Approximately two rounds of samples were prepared during project development so the pouch structure and functional behavior could be evaluated before mass production.
Early Leakage Issue Identified
During the early evaluation stage, some pouches showed leakage risk around the internal separation area during transportation. This indicated that the sealing condition still required adjustment.
Sealing Temperature Adjusted
Runlong Pack fine-tuned the sealing temperature to improve the balance between keeping the internal separation secure during handling and allowing deliberate activation by the consumer.
Manual Squeeze Testing
Manual squeeze tests were used to evaluate whether the internal release function could be activated intentionally without becoming too easy to open during normal handling.
Sample-Based Inspection
Samples were checked during the refinement process to compare functional performance and confirm that the adjusted sealing condition was suitable for continued project preparation.
Customer Confirmation
The customer later reviewed the project in person at Runlong Pack and confirmed the pouch requirements during the factory visit before production follow-up continued.
Sampling, sealing adjustment, manual squeeze testing and customer confirmation were used together to reduce the risk of moving directly from concept to full production without functional evaluation.
Batch-by-Batch Sampling During Production
After the project moved into production, Runlong Pack continued sample-based checks during each production batch rather than treating approval of the initial sample as the end of quality control.
Samples were taken from each production batch for review.
The pouch’s intended release behavior remained part of the inspection focus.
Seal condition was reviewed as part of ongoing production quality checks.
Production sampling helped maintain consistency after final project confirmation.
Exact sealing temperatures, internal construction details and proprietary pouch parameters are not published in order to protect the customer’s product design and project confidentiality.
Project Result
From Functional Development to a 200,000-Pouch Production Order
After sampling, sealing adjustments, functional testing and in-person confirmation, the project progressed into mass production with continued batch-by-batch sampling inspection.
A Functional Pouch Concept Prepared for Commercial Production
The project moved from an unusual functional packaging concept through approximately two rounds of sampling and refinement. An early leakage risk around the internal separation area was identified, the sealing condition was adjusted, and the pouch was evaluated through manual squeeze testing and sample-based inspection.
The customer later reviewed the project in person at Runlong Pack and confirmed the pouch requirements on site. The final order proceeded into production for 200,000 custom-shaped spout pouches.
Approximately two rounds of samples supported project development.
The customer reviewed and confirmed project details during the factory visit.
Batch-by-batch sampling continued during production.
More Than Printing a Custom Pouch
Functional packaging projects can require repeated evaluation, adjustment and direct customer communication. This project demonstrates how Runlong Pack approaches custom pouch development when the package itself has a functional requirement beyond conventional product containment.
Support for pouch projects requiring non-standard shapes, formats or functional requirements.
Samples can help identify functional issues before moving directly into a larger production order.
In-person project discussions supported clearer communication around functional pouch requirements.
Batch-by-batch sampling remained part of the production quality-control process.
Client identity, finished product artwork, proprietary internal construction details and specific production parameters are not disclosed at the customer’s request. Factory-visit photographs are published with the customer’s permission.
Discuss Your Custom Packaging Requirement with Runlong Pack
Tell us your pouch format, intended use, size, material requirements and functional goals. For non-standard projects, our team can review the packaging requirements and discuss appropriate sampling and production preparation.