BakPac scales pouch production with seventh installation

BakPac has inreased its output to handle increasingly complex job requirements, marking a further step in BakPac’s ongoing investment strategy.

The site now operates five Galaxy pouchmakers alongside two HP Indigo 200K digital presses. The latest installation replaces an earlier-generation machine installed in 2023 and brings the company’s pouch-converting equipment to a fully standardized specification.

BakPac has removed a key limitation often faced in flexible packaging production which is machine-specific job allocation.

Harvey Dailly, production supervisor at BakPac, said the upgrade has already had a tangible impact on operations.

‘Bringing all our pouchmakers to the same standard gives us the flexibility to run any job on any machine. That makes a significant difference in how we plan production and respond to customer requirements,’ he said.

The investment comes as BakPac reports strong production volumes at the start of 2026. In the first three months of the year, the company produced more than 12 million pouches across over 500 individual jobs.

This output reflects a production model increasingly geared toward handling both high volumes and high job variation, an ongoing challenge across the flexible packaging sector. Run lengths at the site currently range from as few as 500 units to several hundred thousand, supporting a mix of co-packers, established brands, and emerging businesses.

The ability to manage this spread of job sizes is being enabled by the combination of digital printing and standardized converting, allowing faster changeovers without the efficiency losses typically associated with shorter runs.

BakPac’s approach mirrors wider shifts in packaging demand, where brand owners are seeking shorter lead times, increased SKU variation, and more responsive supply chains. These pressures are pushing converters to rethink traditional production models that prioritized long runs and limited variation.

Harry Baker, sales and operations at BakPac, said the latest installation is intended to address this shift directly.

‘There’s often an assumption that scale and flexibility sit at opposite ends of the spectrum. What we’re building is a system where both can be achieved simultaneously,’ said Baker.

The integration of digital print technology with pouch converting is central to this strategy, enabling faster turnaround while maintaining consistent output levels.

The latest investment underlines a broader trend within the industry: a move toward more agile, digitally enabled production that’s capable of handling a growing mix of job types without sacrificing scale.