Skip to content

Flexible Pouches vs. Rigid Packing: Why the AeroFlexx Pak Is the Better Option

, , | November 6, 2025 | By

As today’s brands focus on providing consumers with eco-friendly, durable, and easy-to-use packaging, the market demands innovative alternatives to traditional rigid and flexible packaging. Constructed with the best features of both formats merged into a single solution, the AeroFlexx Pak redefines what sustainable packaging can be, offering brands and consumers a flexible and cost-effective liquid packaging solution.

 

The Challenges of Rigid and Flexible Packaging

Both rigid and flexible packaging require closures and added pieces, such as caps, lids, and pumps. These parts aren’t always recyclable. Additionally, when shipped, extra materials are often required to help limit leaks and spills. 

The consumer dispensing experience for a lot of rigid and flexible packaging options can be unpredictable. Sometimes, more product comes out than intended, and other times, it can be difficult to get all the contents out of the packaging. This not only contributes to waste but can also be frustrating for consumers.

 

How the AeroFlexx Pak Outperforms Other Options

AeroFlexx liquid packaging combines the lightness and durability of flexible packaging, but, similar to rigid packaging, it doesn’t lose its shape. It’s also recyclable, easy to ship, and offers an easy dispensing experience for consumers.

Here are three areas where AeroFlexx Paks are a better option than rigid and flexible packaging:

 

1. Environmentally Sustainable Packaging 

According to a report, only 9 percent of plastic worldwide is recycled, and, unfortunately, flexible and rigid packaging may be less sustainable than many think. Many of these packaging solutions are made with multiple components, such as pumps, wrapping, and induction seals. Given these mixed-plastic components, the packaging isn’t always recyclable. 

Alternatively, the AeroFlexx Pak offers brands a single-component packaging solution that opens with just one tear. As a result, it uses 70 percent less plastic up front than plastic bottles. The Pak isn’t only recyclable but also addresses recyclability at the source because it’s made from 50 percent recycled content.

The AeroFlexx Pak also promotes sustainability during shipping. When unfilled, Paks ship flat, so more of them fit into every box. As a result, there are fewer trucks on the road, lower carbon emissions, and a much simpler supply chain. Once empty AeroFlexx Paks reach their destination, they’re ready for filling and distribution across all of your retail channels.

 

2. Easy Dispensing Experience

The whole point of adding caps and pumps is to prevent waste and help consumers dispense only what they need. But these closures aren’t always as precise as they should be. Sometimes, rigid containers leave a lot of product inside. And because many closures are add-on parts and pieces, they can leak and get damaged during shipping.

The AeroFlexx Pak has a built-in self-sealing valve that allows users to dispense the amount they need. There’s no separate dispenser, and Paks are also leak-resistant. As a result, consumers can dispense liquids more precisely without worrying about waste, spills, or leaks.

 

3. A Simpler Supply Chain

The AeroFlexx Pak doesn’t require labels or molds; it offers superior packaging in a single all-in-one pack. With this simplified sourcing, there is a quicker filling and shipping process with no unnecessary packaging materials.

In place of separate labels, AeroFlexx Paks offer greater brand creativity. They can be customized by size, shape, design, and 360-degree artwork—all without the equipment, inventory space, and shipping expenses that separate labels require.

 

A More Innovative Packaging Solution

Traditional flexible pouches and rigid packaging options have their share of advantages and disadvantages. The AeroFlexx Pak combines the best of those solutions to offer a superior, integrated alternative that truly meets the demand for sustainable packaging, delivers an enjoyable dispensing experience, and enables unique custom product packaging for true brand differentiation.

You've seen how AeroFlexx solves the immediate problems of leaks, supply chain complexity, and waste. The next step is to understand how this packaging innovation translates directly into bottom-line growth and market share expansion for your brand.

To learn more about how AeroFlexx is revolutionizing liquid packaging and transforming packaging costs from an expense into a strategic asset, download our complimentary guide: Transforming Packaging into a Strategic Growth Driver.