AB Sports Nutrition

When new customer in the sports nutrition sector, AB Sports, approached us looking for packaging, their primary goals were to achieve cost savings in storage and distribution while ensuring the format maintained product freshness and strength. The solution also needed to be fully recyclable and capable of holding a substantial weight.

They were committed to sustainable packaging, requiring a fully recyclable option. Protein powder needs to be protected from moisture and oxygen to maintain freshness, necessitating a high-barrier material.

Additionally, the packaging had to withstand the weight of 5.4kg of product while also presenting well on retail shelves. The customer also required a generic printed bag to allow label application for different SKUs based on demand.

What did we do?

Law Print proposed a Stand-Up Pouch made from a recyclable material structure. The material composition included high-barrier MDOPE and EVOH LLDPE films. MDOPE (Machine Direction Oriented Polyethylene) ensured high mechanical strength to support the 5.4kg weight, while EVOH (Ethylene Vinyl Alcohol) provided excellent oxygen and moisture protection to preserve product freshness.

The structural design featured a K-Seal construction for optimal weight distribution and shelf stability. With all seals at a minimum of 10mm, the bottom seal enhanced durability. A zipper closure was added for resealability and consumer convenience, along with easy open cuts and rounded corners for a user-friendly experience. Printing was done using Rotogravure in 5 colours with 100% ink coverage.

The compliments of flexible pouches provided the customer with several key benefits. The MDOPE/EVOH LLDPE structure ensured full recyclability while offering necessary barrier protection. The EVOH layer prevented moisture and oxygen transmission, maintaining the protein powder’s freshness. The K-Seal design allowed the pouches to sit well on shelves, ensuring a strong branding presence, and the generic printed bag enabled easy over-labelling based on product variations and demand.

By using high-barrier, recyclable K-Seal pouches, the customer achieved a cost-effective, sustainable, and practical packaging solution that improved their logistics, product protection, and shelf appeal. This case exemplifies how innovative, flexible packaging can deliver operational efficiencies while supporting sustainability goals.