By Bev Hermanson

Here’s a challenge for you.

Next time you walk into a grocery store, see if you can count how many brands use this handy type of packaging.

In the packaging industry, it’s referred to as a Doypack and it was invented and patented by Louis Doyen back in 1963.

THE NEED

Doyen was the CEO of Thimonnier, a French company that manufactured packaging equipment. He knew that the best way to sell machinery was to come up with innovative solutions and, in this instance, his quest was to provide a flexile packaging solution for food manufacturers – one that would preserve the freshness and texture of the contents.

However, as the invention was protected by a patent, there was a slow response from the marketplace and it was only post-2004, when the patent expired, that the use of Doypacks grew exponentially. Now, wherever you go, you’ll find them on supermarket shelves, in pharmacies, pet stores, hardware stores and just about everyone’s pantry.

WHAT EXACTLY IS IT AND WHY IS IT SO POPULAR?

In essence, the Doypack is a stand-up pouch that has fairly rigid front and back panels sealed along the sides and a gusset at the bottom that provides a stable base once the pouch is filled with product. The pouches are normally supplied flat, with the gusset forming a w-shape between the two outer sides.

However, it’s actually the tops of the pouches that give this design the greatest versatility.

Many large pouches, such as the ones with square bottoms that contain dried dog food, might come with a ziplock and a top seal. Strip away the top seal and after the contents are dispensed, the package can be resealed using the zip lock.

Another resealable option is the screw top that’s often used for cold drinks, baby food and liquid soap refills.

SOUTH AFRICA LEADS THE WAY

One of the first uses of Doypacks in South Africa was the packaging of olives for export.

For the local market, Ina Paarman’s Kitchen, (founded by well-known foodie, Ina Paarman and her son, Graham), chose the Doypack for the sauces that they launched through the Woolworths stores that served the affluent, more discerning sector of the market .

Initially, they used a plain see-through material for the sides, with pressure-sensitive labels for the branding and instructions. As time went on, the composition of the pouches became more sophisticated and you’ll now see many of their Doypacks incorporating a metallic layer as well.

WHAT ARE SOME OF THE ADVANTAGES OF DOYPACKS?

• They are supplied flat, saving space during transportation to the manufacturer.
• They are not as heavy as some of the more rigid containers, such as glass and metal.
• They don’t need ‘secondary’ packaging such as an outer sleeve or outer box.
• They can include materials that block out UV light.
• They can hold liquids, powders and solids, making them ideal for a wide range of applications, such as foods, beverages, health products, cosmetics, pharmaceuticals and even some industrial chemicals.
• They can be printed with multicoloured designs to improve the visual appeal of the products.
• The resealable caps and ziplocks allow multiple dispensing of the products.
• Airtight storage also helps to extend the shelf life of some of the products.

ARE DOYPACKS RECYCLABLE?

Doypacks made from a single material, such as polyethylene (PE) or kraft paper combined with a heat-sealable synthetic material may be recyclable. But as soon as the construction becomes multi-layered, such as a lamination of foil between plastic layers, it becomes too expensive, if not impossible, to recycle the end product.

In the case of Doypacks having to be sent to landfills, the only upside is the fact that Doypacks compress well and therefore take up less space.

One can imagine that, in the early days of plastic packaging, innovators such as Louis Doyen did not think as far as the end of his creation’s life cycle.

But now that plastic waste has become an absolute environmental disaster, one may wonder if the best solution to this dilemma would be to ship these sophisticated creations back to their originators and let them provide the answers to the plastic pollution impasse.

What do you think? Do the advantages outweigh the negatives?

#flexiblepackaging
#doypack