Crisps, biscuits, confectionery or frozen vegetables… A large share of packaged food on supermarket shelves is packed in pillow bags. The format is named after the puffy pillow shape it takes when filled, and it is one of the most common and efficient formats in flexible packaging.
How is a pillow bag formed?
Pillow bags are usually not supplied as pre-made pouches but are formed directly on the production line from roll film. A vertical or horizontal form-fill-seal machine:
- Forms the film into a tube and seals it lengthwise at the back (back seal),
- Seals the bottom edge,
- Fills the product,
- Seals and cuts the top edge.
This process takes place on a single machine at high speed, which is the main reason the format is so economical.
Two back seal options: fin seal and lap seal
- Fin seal: The two inner surfaces of the film are sealed together, and the seal stands outward like a “fin”. A common and reliable method.
- Lap seal: One edge of the film overlaps the other, and the inner surface is sealed to the outer surface. It uses less film but requires both surfaces of the film to be sealable.
Which method is used depends on your machine and film structure, so it should be clarified with your supplier before ordering.
Benefits of pillow bags
High speed: Form-fill-seal lines can produce a large number of packs per minute.
Low unit cost: No pre-made pouch production or extra processing is needed, so packaging cost is low.
Less material: The simplicity of the format reduces unnecessary material use.
Protective atmosphere: Inert gas can be flushed into the pack before sealing, protecting the product from crushing and supporting shelf life. That is why crisp bags are puffed up.
Suitable products
- Crisps and snacks
- Biscuits, crackers and wafers
- Confectionery and chewing gum
- Pasta
- Frozen foods
- Tea and coffee (single-serve)
- Hardware and small parts
Limitations
Pillow bags cannot stand upright; they are usually laid flat, hung or displayed in cartons. For products where shelf visibility is critical, a doypack or flat bottom pouch may be more suitable.
Frequently asked questions
Should I order bags or roll film for pillow packs? If you have a form-fill-seal machine, you order roll film. For film parameters, see our auto machine roll films page.
Can a zipper be added to a pillow bag? It is possible with some line configurations, but if reclosability is the priority, pre-made zipper pouch formats are the more practical solution.
Efficient packaging for high-speed lines. Explore pillow bags → · Get a quote →