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Popcorn Packaging

Custom Printed Popcorn Packaging to Beat the Competition

Custom Popcorn Packaging

Popcorn is one of the most popular snacks in the United States. It's been enjoyed by humans for hundreds of years. In fact, scientists have found evidence of popcorn in 1,000 year old peruvian tombs. Popcorn first became an American staple in the late 1890's when an entrepreneur from Chicago invented the first popcorn-popping machine. Nowadays, popcorn, both in kernel form or fully-popped, is found in the snack aisles of supermarkets and other retail outlets across the country. 


CarePac specializes in using high-quality flexible barrier film to create custom packaging for your popcorn products. Popcorn is considered a healthy snack, full of flavor and fiber. The last thing customers want is popcorn that's chewy and stale. Protecting your product from moisture and oxygen is what keeps your corn fresh and crunchy. We know how to layer different barrier films to create airtight packaging that locks in flavor and extends the shelf life of your popcorn so it's ready for your customers to enjoy. 

Custom Pouches Perfect For Your Popcorn Packaging Needs

Stand Up Pouch

The stand up pouch is the most popular flexible barrier configuration we make. These bags are outfitted with a bottom gusset, that when deployed, allows the pouch to "stand up" on a shelf in a store. Add features such as a zipper closure and a tear notch for extra convenience. This pouch is great for both kernels and fully popped corn.

3 Seal Pouch

With a 3 seal pouch configuration, you load the the popcorn in the same way your customer would remove it - through the top. Additionally, bags with a zipper closure could be used without heat-sealing. 3 seal pouches pack well in standard cardboard boxes, saving you money when shipping your product to retailers.

Tamper Evident Pouches

Tamper evident pouches are widely used because of their ability to be easily and quickly filled with product. In a tamper evident configuration, the top of the pouch (above the zipper) is pre-sealed during the pouch creation, and the bottom is left open. This allows you to fill the pouch without having to contend with the zipper, or worry about inaccurate heat seal placement. 

Popcorn Packaging Designed for Top-Shelf Product

CarePac understands the needs of small and medium-sized popcorn distributors. Our custom packaging offers a professional appearance — like the packaging used by Fortune 500 companies.

We Save You Money

Even with smaller budgets we offer you the opportunity to compete with the biggest popcorn brands in the industry.

Fast Shipping

We offer some of the fastest packaging lead times in the business. Expedited lead times for digital and plate printing come in at 4 weeks and 5 weeks respectively. 

Lock in Freshness + Flavor

Packaging your popcorn in flexible barrier packaging keeps your popcorn fresher for longer, and makes storage simple for your customer.

Low Minimum Order Quantities

Print and customize as few as 1,000 popcorn bags (5,000 bags on some configurations and sizes). 

Art & Design Services

Need a logo or design? No problem! We provide brand design services to help you create the branded custom packaging your product deserves. We'll get your product to stand out from the crowd!

FDA Approved & Kosher

All our packaging for popcorn is FDA approved, Kosher, TSE free, BPA free, and Sulfer & Phthalates free.

Avoid the China Trap

Purchasing pouches from China does not provide cheaper or faster alternatives, like many small and medium sized businesses have been made to believe. In fact, many of our current clients have encountered problems when ordering from China due to the language barrier, the lack of compliance documentation, longer lead times and, above all, higher tariffs. 

High Quality Pouches Start with the Right Material

CareSilver

CareSilver is our silver barrier material that offers a great barrier to cost ratio. These pouches are strong, durable, and a wonderful surface for your custom printing. This material is compatible with both custom digitally printed pouches, or plate printed pouches. CareSilver comes in both a Gloss, Matte, or Custom finish. 

CareClear

CareClear is a clear base material. That means you can use it to build windows into your custom bag to see the food inside. CareClear comes in many variations but all of them can be custom printed, both digitally or plate printed. CareClear is an attractive choice for your bags where viewing windows are allows by your state's laws. 

CareFoil

CareFoil is our highest barrier material. In essence it is like putting your food inside an aluminum can, but in this case it's a flexible pouch with an aluminum foil layer of protection. Don't worry your product never actually touches the aluminum, but you get all the benefits of using it, including maximum shelf life and retained potency of your product. 

Custom Flexible Barrier Film Packaging

Here are some of the configurations available for custom food packaging.

Stock options can offer typical unit sizes for your food packaging, however, if you find your company’s needs are different than stock sizes, flexible barrier packaging allows for creating the size best suited to your needs.

Choosing the Right Flexible Barrier Popcorn Bags

Flexible barrier packaging is a great solution for preserving the freshness of your popcorn products.

There are certain considerations that should be taken into account when deciding on the right type of barrier packaging bags for your popcorn. How long is your product going to be in the package? What is the required shelf life? How important is the freshness of your product?


Stand up bags offer many unique benefits over traditional popcorn packaging containers. First let's look at convenience. Customers want a package that easy to open and reseal to keep their favorite snack fresh. Configuring your flexible popcorn containers with a tear notch coupled with a recloseable zipper gives the end-user the best of both worlds. Plus, as a manufacturer,  you get to save costs. Pouches and bags are flexible and lightweight - you can pack more items into a shipping container and less weight equals savings on shipping costs. 

Think about these questions as you consider your packaging needs:

  • Where will my product be sold?
  • Are there space constraints, or retail requirements?
  • How much product do you need in each pouch?
  • Will the product be stored on a Shelf? Does it need
          a hang hole?
  • How is it transported? Air freight is subjected to
          higher pressures than truck shipments.
  • What is your "fill philosophy" - how much product do
          you want in the packaging?
  • Is your product single-use or multi-use?

These are just some of the questions our packaging specialists will walk you through as we prepare to create your custom flexible barrier packaging. We are here to serve!

Not Ready for a Custom Order? Check Out Our Bags In Stock + Ready to Ship

CareClear 2x3 - 100 Pack

CareClear 2×3 – 100 Pack

From $7.99

CareWhite 3.5×4.5 – 100 Pack

CareWhite 3.5×4.5 – 100 Pack

From $16.99

CareBlack Child Resistant 3.75×6×2 (1/8 oz) – 100 Pack

From $39.99

CareKraft 4×6×2.5 – 100 Pack

CareKraft 4×6×2.5 – 100 Pack

From $20.99

Popcorn Packaging FAQs

Whether you are new to custom printed packaging or a seasoned pro you may have a few questions about our products and process.

Q: Do you offer wholesale pricing when buying popcorn packaging in bulk?

Yes, with CarePac you can save even more with our everyday, wholesale pricing available on our stock bags.

Q: Do you offer custom sized popcorn bags?

Looking for a more specific pouch size for your popcorn packaging needs? We have got you covered. We have come to understand that sometimes our clients are looking for something more specific in their bags. A specific size or configuration – that is why we offer custom-sized bags to meet these needs. We make it fast and easy. We make them so you can even use your artwork and designs. Whether you need food-grade custom pouches, or tamper-evident packaging, we’ve got you covered. 

Q: Can I print my own design on my custom popcorn packaging?

Depending on your needs and preference, we offer custom printing both digitally and with the use of plates. While digitally printed bags come with several advantages, we sometimes advise clients to opt for plate printing depending on their needs. Mostly because plates offer the lowest per-bag price points. However, digital prints offer a more robust color count and are its best for short run usage. Whichever the case, we always have a support staff to walk you through the production process and help you identify which printing is best for your project.


Q: What if I need help designing my popcorn packaging?

You don’t have to bring press-ready art. There are many technical considerations when printing barrier films, and we do all that work for you. We’ll take your original art files and set them up for printing to ensure you get the best quality printing and develop digital art proofs that you can revise. We focus on providing custom printed pouches and barrier packaging that meets your budget.

Q: What is the standard lead time on a custom printed popcorn bag?

In our industry, contrary to what you might think, a ten-week lead time is not uncommon. We offer the best lead-time options on all our food packaging quotes compared to other brands. Our lead time list for custom packaging bags is:

Un-Printed Custom Sized bags: 2 weeks.

Digital printed: 4 weeks expedited, 8 week standard.

Plate printing: 5 weeks expedited, 9-10 weeks standard

Q: How much do custom printed bags cost?

Check out our free online instant calculator to get a cost for your bags.

Q: What is your Minimum Order Quantity for printed popcorn bags?

Printed food packaging bags and pouches we offer as low as 1,000 for digital and as low as 5,000 for plate printing. We strive to provide high quality printing services and materials in a low price.

Care Design™

Make Your Product Fly Off The Shelf With Custom Printed Pouches

When it comes to custom printed popcorn packaging - customers buy with their eyes first. Great packaging can mean the difference between someone trying your product, or bypassing yours for a competitor’s.

And nothing pulls their focus more than attention-getting, custom printed packaging!

When you’re ready to design a custom printed bag, our experienced retail design consultants will help you create a look that will make your product SELL.

Digital

Great for bags with a high color count, many SKUs or, low quantities

Flexographic

Surface printing for compostable bags

Plate Printed

Lowest per-unit cost, great for many production grade projects

New to Custom Packaging?

Check out our process below and then get an instant quote.
Step 1:
Material Selection
Step 2:
Sizing and Configuration
Step 3:
Master Art Proofs
Step 4:
Material Is Printed
Step 5:
The Bags Are Made!
Step 1: Instant Online Quote

Every custom bag we print goes through a very specific set of steps, from choosing your bag size, material and configurations, to proofing, to final delivery. With more than 10 years experience, we will walk you through every step of the process to ensure your bag will fly off the shelf.

We make it easy for you to get an instant online estimate using our bag calculator. Choose how many bags you want, how soon you need them, what type of bag you want and what features you want. Get a free instant price quote today!

Or feel free to give us a call. We’re happy to help.

Step 1: Instant Online Quote

Every custom bag we print goes through a very specific set of steps, from choosing your bag size, material and configurations, to proofing, to final delivery. With more than 10 years experience, we will walk you through every step of the process to ensure your bag will fly off the shelf.

We make it easy for you to get an instant online estimate using our bag calculator. Choose how many bags you want, how soon you need them, what type of bag you want and what features you want. Get a free instant price quote today!

Or feel free to give us a call. We’re happy to help.

Step 2: Sizing and Configuration

Pick the exact right size custom printed pouches for your product. All custom printed pouches that we sell can be custom sized, with custom die-cut windows, or other unique configurations. Generally if it is possible with a flexible material then we can supply your custom printed pouches, not a problem.

Because printing occurs before the bag or pouch is made, (we print the roll stock), sizing and configuration is totally customizable to your specifications. You can customize the size of your package to exactly what you need.

Step 3: Master Art Proofs

You don’t have to bring press ready art. There are many technical considerations when printing barrier films, and we do all that work for you. We’ll take your original art files and set them up for printing to ensure you get the best quality printing, and develop digital art proofs that you can revise. We focus on providing custom printed pouches and barrier packaging that meets your budget.

Step 4: Material Is Printed

We offer Digital, Plate, and cylinder printing options for making your custom printed pouches. So once the material rolls are cut, treated, they are then printed, and finally any lamination is applied (matte, gloss etc).

Step 5: The Bags Are Made!

The printed material is then made into your bag.We offer a selection of finishing laminations, and varnishes for your custom printed pouches.

Why Choose CarePac

On Time. Every Time. Guaranteed.

Highest quality pouches for whatever your project requires

Low Minimum Orders

Absolute Best Customer Service. Talk to a real person, in the United States, who is an expert on choosing the ideal bag for your products.

Confidence Your Order Will be Done Right

5% Price Match Guarantee

Now You Really CAN Have The Highest Quality at the Best Price

We will match any competitor's price within 5%, guaranteed. That means you don’t have to settle for an inferior product just to save money.

You can have the BEST stand-up pouches on the market — along with our legendary customer service — for practically the same price!

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