What Is Rollstock Packaging? A Complete Guide to Rollstock Film and Its Benefits | LPS Industries
- LPS Industries
- Aug 21
- 4 min read
In a competitive and fast-moving packaging landscape, manufacturers and brands across all industries are constantly seeking ways to optimize efficiency, reduce costs, and improve sustainability. One of the most effective ways to achieve these goals is by integrating rollstock packaging into your production workflow.
At LPS Industries, we specialize in advanced flexible packaging solutions—including custom rollstock film—designed to streamline your operations, enhance your product presentation, and maintain the highest standards of protection and performance.
This guide will explore everything you need to know about rollstock packaging: what it is, how it works, its advantages, key applications, and how LPS can help you implement a tailored solution.
What Is Rollstock Packaging?
Rollstock refers to flexible packaging material supplied in large, continuous rolls that are printed or unprinted. This material is fed into form-fill-seal (FFS) machinery, which automatically forms, fills, and seals the packaging during production.
Depending on the machinery used, rollstock film can be adapted for:
Vertical Form Fill Seal (VFFS) machines
Horizontal Form Fill Seal (HFFS) machines
Overwrap, pouching, or flow wrap systems
Rather than using pre-made pouches or bags, rollstock allows manufacturers to create custom packaging formats on demand—directly on the production line.
Why Choose Rollstock Packaging?
Rollstock packaging offers distinct advantages over traditional pre-made bags or rigid containers. It’s a go-to solution for companies seeking flexibility, cost savings, and efficiency, all while meeting high-volume demands.
1. High-Speed Production & Automation Compatibility
Rollstock is designed for use with automated machinery, enabling high-speed, continuous packaging lines. This drastically reduces downtime, increases throughput, and minimizes labor costs.
2. Cost-Effective Material Usage
Using rollstock can reduce costs in several ways:
Lower material cost per unit compared to pre-made pouches
Less storage space required for raw materials
Greater yield from each roll with minimal scrap
Ideal for long production runs and large-scale manufacturing
3. Customizable & Configurable
Rollstock is extremely versatile and can be configured to meet a wide range of application needs:
Pillow pouches
Stick packs
Four-side seal pouches
Gusseted bags
Zippered pouches (with pre-applied closures)
Die-cut windows, perforations, hang holes, and more
At LPS Industries, we can customize rollstock film with high-barrier structures, custom gauges, and print-ready finishes to align with your branding and functional requirements.
4. Sustainability Benefits
Rollstock packaging uses less material than rigid packaging or pre-made formats. That means:
Lower carbon footprint per unit
Reduced transportation weight and fuel usage
Less packaging waste
Compatibility with recyclable, compostable, or PCR (post-consumer recycled) materials
Sustainable rollstock solutions are a core offering at LPS, aligning with our clients' ESG goals and compliance requirements.
What Can You Package With Rollstock?
Rollstock is used in a broad spectrum of industries, thanks to its formability, barrier performance, and printability.
🥗 Food & Beverage
Snacks (chips, nuts, trail mix)
Frozen foods and ready meals
Coffee and powdered drinks
Granola bars, jerky, protein snacks
Sauces, soups, and liquids in stick packs or pouches
🧴 Health, Beauty & Personal Care
Face masks, single-use creams, and lotion packets
Soaps, wipes, and cleansing pads
Vitamin powders and supplements
🧰 Industrial & Household Products
Detergent pods, fertilizer sachets, small hardware parts
Medical devices and sterile tools (with sterilizable films)
💊 Pharmaceutical & Nutraceutical
Over-the-counter drugs
Single-use dose packaging
Powders, capsules, tablets
LPS Industries provides rollstock solutions tailored to each sector’s regulatory, barrier, and shelf-life requirements.
How Is Rollstock Manufactured and Printed?
Rollstock is typically made from multi-layer laminated films that may include materials such as:
Polyethylene (PE) – excellent seal strength and flexibility
Polypropylene (PP) – moisture resistance and heat tolerance
Polyester (PET) – high tensile strength and clarity
Foil or metallized layers – for enhanced barrier protection
What Is Rollstock with Pre-Applied Zippers?
A major innovation in rollstock technology is pre-applied zippers or reclosable features integrated into the roll film. This allows brands to:
Offer convenient resealability
Improve customer experience
Reduce product waste
Maintain freshness over multiple uses
LPS Industries offers rollstock with pre-applied zippers, designed to integrate seamlessly into automated packaging lines, eliminating the need for secondary processes.
Sterilization and Barrier Protection
Rollstock can be engineered for sterile environments, especially for food and medical applications. Options include:
Coatings for peroxide or steam sterilization
High-barrier films for oxygen, moisture, UV, and aroma protection
Tamper-evident seal formats
Our packaging specialists work with you to identify the right material composition and sealing method to ensure compliance with FDA, USDA, or pharma-grade standards.
Why Choose LPS Industries for Rollstock Packaging?
At LPS Industries, we deliver more than just film—we deliver fully integrated flexible packaging solutions. Our clients trust us for:
Custom-engineered rollstock films designed to exact specifications
In-house printing, lamination, and slitting
Pre-applied reclosable features (zippers)
Low minimums and large-volume capabilities
Sustainability-focused materials
Exceptional customer support and rapid turnaround
Whether you’re just starting to explore flexible packaging or looking to scale your current operations, we provide the technical expertise, materials knowledge, and production capacity to help you succeed.
Ready to Upgrade to Rollstock?
Rollstock is an ideal choice for companies seeking efficient, cost-effective, and high-quality flexible packaging. From snack food producers to pharmaceutical manufacturers, it provides unmatched value across nearly every packaging application.
Contact LPS Industries today to learn how our custom rollstock solutions can reduce your costs, improve your packaging efficiency, and elevate your brand.
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