BakPac, part of the Bakers group, has fortified its stance in the dynamic refill and liquid pouch sector through a significant investment in two state-of-the-art Totani automatic spout inserters. These machines are now operational at the company’s site in Brentwood.
This enhancement, with a financial commitment exceeding £500,000, signifies a major boost in BakPac’s flexible packaging capabilities, enabling brands to access high-quality digitally printed spouted pouches swiftly and at scale.
The new equipment arrived on August 6, and installation commenced the following week. Engineers from Totani dedicated four days to on-site commissioning, followed by comprehensive operator training over the next week. Both inserters are now actively producing, with additional testing in progress as BakPac optimizes throughput and fine-tunes its operations.
For BakPac’s clients, this strategic investment translates into increased production capacity, enhanced flexibility, and quicker turnaround times for medium to long-run spouted pouch projects. The new machines accommodate both top and corner spouts, initially offering sizes of 10mm, 17.5mm, and 21.5mm, across pouch dimensions ranging from 50ml to 5 liters. This range provides brands with numerous choices for their refill packaging, liquid goods, and lightweight substitutes for traditional rigid containers.
Steve Baker, managing director, noted that this proactive decision to invest highlights BakPac’s long-term vision regarding the refill market and the rising demand for spouted solutions in various industries.
“Spouted pouches present an exciting opportunity for BakPac,” he stated. “The UK refill market is still in its nascent stages, but we believe it’s a matter of timing before demand escalates. We aimed to invest now to master the process and ensure we possess the capacity and expertise required as market growth accelerates.”
Baker remarked that this capital infusion also paves the way for new trade supply prospects. “We recognize that other pouch manufacturers in the UK might lack the dedicated spout insertion capabilities or the capacity for large-scale spouted pouch projects. By investing in two Totani machines upfront, we are positioning BakPac not just to support brands, but also to provide a premium trade solution in response to the increasing interest in spouted formats.”
The newly implemented inserters seamlessly integrate with BakPac’s digital printing and pouch converting operations, facilitating a smooth transition from prototype to full-scale production without the need for multiple suppliers. Additionally, BakPac’s recyclable mono material has successfully been processed through these machines, addressing customer needs for more sustainable refill packaging options.
Importantly, this investment alleviates one of the primary bottlenecks in spouted pouch production. As spout insertion occurs towards the end of the manufacturing process, following printing, laminating, and pouch conversion, ensuring high-speed reliability is crucial for maintaining quality and meeting delivery deadlines.
“Spout insertion is among the last steps in our production; thus, safeguarding quality and delivery schedules is vital,” Baker explained. “With the capabilities provided by two Totanis, we can effectively support customers as they scale—whether they are trialing new refill innovations, transitioning to larger-volume repeat productions, or seeking a reliable trade partner with specialized spouted pouch expertise.”
The installation and operational setup of the machines were managed by Bakers’ facilities and maintenance team, embodying the company’s enduring commitment to reinvestment and continuous improvement. Already, conversations are ongoing regarding additional investments in spout inserters as market demand continues to rise.