Refill Pouches

Custom Printed Refill Pouches for Soap, Lotion, Cleaners, and Body Care

What refill pouches are used for

A refill pouch is a flexible bag that holds more product than a standard bottle, and it is made to refill a bottle, a jar, or a dispenser. The customer buys the pouch, pours it into a bottle they already own, and keeps using that bottle. Brands use refill pouches for liquid hand soap, body wash, lotion, shampoo, conditioner, dish soap, and household cleaners. A refill program lowers the amount of rigid packaging a customer buys, and it gives you a repeat purchase. Refill pouches are light and ship flat before they are filled, which also cuts the cost of freight.

Sizes and how to measure

Refill pouch size is written as width x height x bottom gusset, plus a spout size. Choose the size by the volume of the bottle the customer will refill, so one pouch fills the bottle once or twice. A 250 ml to 500 ml pouch suits a hand soap or lotion bottle, and a 1 L pouch suits shampoo and body wash. Larger pouches suit household cleaners. Leave a little room at the top, because pouches are not filled to the brim. The spout size sets how fast the product pours, and a thick product needs a wider spout than a thin one.

Example sizes (approximate and for reference only; we confirm the exact size before you order):

• 250 ml: about 4.5 in x 6.5 in x 2 in
• 500 ml: about 5.5 in x 8 in x 2.5 in
• 1 L: about 7 in x 10 in x 3 in
• 2 L: about 8.5 in x 12 in x 3.5 in

Materials, spouts, and eco options

Refill pouches are made from layers of film. The layers give the pouch its strength and its barrier against light and air, and the right mix depends on your product. Pouches come in clear, white, matte, glossy, and metalized film. The spout and cap come in several sizes and colors. Many customers ask about biodegradable refill pouches and compostable refill pouches. Those terms have specific meanings, and a pouch only breaks down in the right conditions. Tell us your goals during the free consultation, and we share which film options are available for your product and what each does and does not do. We do not make an eco claim on your pouch that we cannot support, and we suggest you check what you can print on your own pouch.

Printing and finishing

Custom refill pouches are usually printed in full color on the front and back, with a matte or gloss surface. The front panel can show your brand, the product name, the scent, and the size, and the back can show how to refill the bottle. Clear steps on the pouch help the customer, such as pour slowly, shake gently, and close the cap. Keep the main message near the center of the front, and keep important text away from the seals and the spout. At a large run size, the same design can be printed on every pouch, and you can plan several designs for one collection.

Labeling notes

If your pouch holds a product for sale, the label must carry the text that the law requires for your product, such as ingredients, net contents, and warnings. You supply the text and the layout, and we print what you send. We do not write or check label text or claims, so please have your final label reviewed by a person who knows the rules for your product.

Orders from 10,000 units

Orders start at 10,000 units. A run of this size suits an established product, a refill program, or a large launch, and it brings a lower cost per pouch. Wholesale orders can be planned in several sizes and repeated as sales grow. Share your expected yearly volume during the free consultation and we plan around it. Pouches arrive empty and you fill them at your own site or with your filling partner.

Artwork and dieline

We send a free dieline that shows the print area, the bottom gusset, the seals, and the spout position on your pouch, so you can see where your artwork goes and where it should stay clear. Supply artwork as a vector AI or PDF file with fonts outlined and images at 300 DPI in CMYK. If you have no artwork yet, free design support and a free consultation are included, and our team can help lay out the logo and the text from your brand colors. You review and approve the artwork before production starts.

How to order custom refill pouches

1. Choose your pouch size, material, spout, and cap.
2. Order a $59 sample kit if you want to feel the film and spout first. The $59 is credited toward your order total.
3. Send your quantity, starting at 10,000 units.
4. Receive your free dieline and add your artwork, or ask for help.
5. Review and approve the artwork and the spout match.
6. Production takes 6 to 8 business days after artwork approval, and your order ships free to one U.S. address.

The final price depends on pouch size, material, spout and cap, printing, finishing, and quantity.

What comes with every order

• Free shipping to one U.S. address
• Free thank-you cards equal to the units ordered
• Free design support, free dieline, and free consultation
• Orders start at 10,000 units
• Eco-friendly materials sourced from certified suppliers