packaging blogs | Maco PKG

dry filling product packaging

What You Need to Know About Dry Filling Product Packaging for Edible and Nonedible Products

By | Custom Contract Packaging | No Comments

Have you perfected your dry product and are now searching for dry filling product packaging? Maybe you’re not sure where to go to find the right packaging that will help your dry product …

  • Stand out on the shelf
  • Avoid outside contamination
  • Maintain quality, freshness, and taste

And that’s not even mentioning product packaging that should meet sustainability requirements! Flexible bags and stand-up pouches are a great option for dry products, especially edibles from the food and beverage industry. With multiple layers of material, the packaging offers a durable barrier to moisture, punctures, rips, UV rays, grease, dust, impurities, and other hazards.

Edible Items to Dry Fill:

  • Sweeteners
  • Sugar
  • Flour
  • Salt
  • Dry ingredients
  • Nutritional supplements
  • Spices
  • Herbs
  • Nutraceuticals (like protein powder)
  • Dried fruit and vegetables
  • Nuts
  • Beans
  • Flax seeds
  • Oats
  • Dry pasta
  • Rice
  • Dog food

Nonedible Items to Dry Fill:

  • Dry makeup powders
  • Granules
  • Confetti
  • Bath salts
  • Screws
  • Nuts
  • Bolts
  • Washers
  • Electrical components
  • Dental equipment

How Does the Packaging Process Work for Dry Filling?

Most dry filling machines contain an auger, a tool with a turning spiral bit, that’s responsible for depositing a specified quantity of product into a bag or pouch. Small, heavy items are usually packaged with a check-weigh filling process, a method that uses the weight of the product to fill the container with a specific number of products.

Avoiding Cross-Contamination

Cross-contamination is a primary concern for dry food products during the packaging stream. The food and beverage industry have strict regulations to ensure the quality of products. One contaminated batch of product can lead to expensive recalls, brand mistrust, and other serious repercussions. Since many dry products are airborne, they need to be packaged in controlled environment rooms.

The dry filling machines in Maco Pkg’s facility contain a sealed conveyor that protects dry product from the packaging facility. All outside contamination is sealed off, so the product is never exposed to the plant’s surroundings.  

Maco Pkg’s Dry Filling Services

Flexible packaging can easily integrate into on-the-go lifestyles. Your dry product packaging, complete with eye-catching custom printing, can appeal to busy consumers while simultaneously preserving freshness, extending shelf life, and offering easy open-and-close features.

We can fit your packages with ingenious die-cut handles, reclosable zippers, dispensing fitments and whatever you need to make your products attractive, user-friendly, and cost-conscious. Flexible packaging also saves shelf space, shipping charges, and carbon emissions, so it can be a big part of your company’s commitment to sustainability.

Maco Pkg’s Dry Filling Product Packaging

  1. We have access to rail lines that go right up to our facility, so we can accommodate large quantities of dry material.
  2. We can supply, mix, blend, or acquire dry products on your behalf.
  3. Packaging for the food and beverage industry demands certified quality assurance. We are ISO:9001:2008 certified, SQF 2000 Level 3, Organic, and Kosher certified. Find out what these certifications mean.  
  4. Our filling machine has 2 unique attachments that allow us to stop and start the packaging process quickly and efficiently, eliminating re-tooling charges or expensive start-up fees.
  5. As a custom manufacturer of bags and pouches for dry products, you get to decide the specifications of your product packaging. We’ll offer guidance and support but you’ll have your say.  
  6. We offer free samples of product packaging for trial promotion or trade show giveaways.   

We always invite interested parties to a consultation to help us understand your goals and objectives with your product packaging. We’ll sit down with you and list your options, offering our expertise and years of experience to guide you in the process. Once we have a firm idea of what your product entails, we move on to the prototype stage to work out kinks and gain practical insight into the success of your packaging.

If you’re interested in getting this process started, call us at 315.226.1000 or request a quote!

packaging industry

Discover Relevant Packaging Industry News at the WNY IFT Expo 2017

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You’re invited to be our guest at the annual

Western NY Institute of Food Technologies ( WNY IFT) Expo!

Tuesday, March 28, 2017

Joseph A. Floreanos Rochester Riverside

Convention Center, Rochester NY

Free admission, Free suppliers directory, Free Door Prize Games!

Enjoy lunch, find out what’s currently happening in the food industry through the Seminar Sessions, and then visit with packaging professionals like Maco Pkg during the Supplier Exhibits!

Want to learn more? We invite you to join us at the BBQ reception following the Expo. Tickets only $25 per person which includes buffet dinner with brisket and pulled pork from Dinosaur BBQ along with condiments and a chance to win a great door prize!  

Welcome Lunch: 11:45AM – 12:45 PM

Seminar Sessions 12:45 – 2:30

Coffee Break 2:30 – 3:00

Supplier Exhibitors 3:00PM– 6:00 PM

Meet over 100 providers of ingredients, equipment, and services to food manufacturing companies of all sizes.

BBQ Reception

6:00 PM – 8:30 PM

Hyatt on Main $25/person

Seminar Schedule

12:45: “FSMA – Preventive Controls for Human Foods” by Carl Moody, Regional Dairy Processing Specialist, Cornell Cooperative Extension 

This seminar will discuss the Food Safety Modernization Act (FSMA), the largest change to FDA in 60 years. Specifically, the event will address how FSMA has changed the food industry, its focus on preventing contamination instead of merely responding to it, and its impact on food professionals, packaging manufacturers, brand owners, and consumers.

1:30: Food and Beverage Trends- Organic and Non-GMO by Stephanie Mattucci, Mintel, Global Food Science Analyst 

Is genetically modified food (GMO) safe for consumers or no? Are organic goods as beneficial as the media claims? Learn the science surrounding these hot topics and get your answers.

Check out full details and register online!

Or call Shirley at 207.839.3064 for tickets!

The Western NY section, Institute of Food Technologists is a non-profit organization dedicated to the growth and continuing success of the food industry in our region.

The first 100 pre-registered attendees will receive an extra gift at check-in, compliments of Crain Walnuts! Invite co-workers! Get a chance to win an Amazon Firestick for each person that includes your name on their registration!

pouch packaging

Why Choose Pouch Packaging for Your Food Product?

By | flexible packaging | No Comments

Are you trying to determine if pouch packaging is right for your food product? A lot of factors impact the success of your product’s sales, and packaging is one major example – including its cost, durability, functionality, and effect on the environment. The packaging you eventually select should highlight your product’s value, safely transport your product, protect it from outside contamination, and effectively persuade end users to purchase.

Successful flexible packaging maximizes the retail value of the product while minimizing space, volume, and weight. The smaller and lighter the packaging, the cheaper the transportation costs. How can your packaging reflect these principles all at once?

Specifications for Pouch Packaging

Food packaging can come in a wide variety to suit the specific needs of your product. Check out these various types of pouch packaging to find the one that best suits your needs.

Valved Pouches

Valved pouches are ideal for some food products. Valves come in a variety of styles with various functionality. One of the most common valves is a one way degassing valve designed to release CO₂ from inside the pouch during the course of the expected shelf life, without allowing O₂ into the package. This method increases the shelf life of the food product by preserving its freshness and allowing gasses to escape. Valved pouches are commonly used to package coffee beans, tea, and other products that give off gas. This packaging can easily be designed for bulk.

Barrier Pouches

Barrier pouches can be constructed with a variety of packaging materials that properly protect the product from outside contamination, including dirt, grease, pollutants, odor, oxygen, and moisture. The utilization of barrier properties helps preserve food products by preventing staleness caused by oxygen or vapor degradation. In addition, barrier pouches can protect the quality, aroma, and taste of food products. Some foods have the tendency to absorb surrounding odors, so the packaging must protect the product from this defection.

Foil Pouches

Packaging is responsible for safely delivering food products into the hands of the end users, and foil is one of the best materials to use to accomplish this goal. The quality of packaging is measured in part by the material’s Oxygen Transfer Rate, or OTR, which indicates how much O₂ can pass through the material in a certain time frame. Foil has an extremely low OTR, which means that very little O₂ will transfer through the material. The food product is safely packaged inside until the seal is broken at time of use.

Custom Printed Pouch Packaging

The appearance of food packaging, including the printing, directly contributes to the marketing of the product. Pouch packaging can be custom printed to effectively display your brand, differentiate among competitive products on retail shelves, and portray the unique value of your product. Flexible packaging, especially standup pouches, offer a billboard effect when staged on the store shelves. We offer up to 10 colors for custom printed pouches, utilizing digital, flexographic, and rotogravure printing for the highest visual appeal. Matte finishes, zone glossing, and windows are all features we provide to help your product stand out in the marketplace.

Custom printed pouches are especially important for food products. According to scientific research, even pictures of food can trigger hunger pains. So displaying your food product on the package can strongly influence shoppers to purchase.

We hope these tips help you decide what kind of packaging to choose for your food product. If you’d like more information about the advantages of flexible packaging, check out this easy-to-read, brief ebook!

Tell Me More About Flexible Packaging!

packaging prototyping

4 Costly Problems to Avoid During Package Prototyping

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Once you’ve refined your product, be it food, retail non-food, industrial application, consumer products institutional non-food, or medical/pharmaceutical, you need to then determine the product’s packaging. During the package prototyping stage, clients have the opportunity to manufacture and test small samples before committing to large manufacturing runs. These samples not only demonstrate the capabilities of the packaging, but can also serve as tradeshow giveaways.

During prototype, several common problems often arise due to the limitations of packaging and their materials. The package prototyping stage helps product owners save costs by analyzing the results of their packaging on a small scale. Do you foresee these 4 issues becoming a roadblock with your product packaging?

1. Package Consumes Too Much Space

When product packaging lacks space-efficiency, product owners pay more in the long run. Bulky packaging, especially rigid packaging, is expensive to ship, since more trucks and vehicles are needed to transport shipments around the nation. More vehicles means more fuel, an additional cost (not to mention increased CO₂ emissions).

Space efficient packaging, on the other hand, not only ships for less overhead, but can fit on retail shelves in greater quantity and claims less space in warehouses and storage units.

2. Package Material Doesn’t Offer Adequate Protection

Packaging can protect the product from moisture, UV rays, and oxygen. During the package prototyping stage, packaging manufacturers conduct tests to ensure the packaging provides a sufficient barrier to degrading substances. If the packaging samples during prototyping contain any flaws with the materials’ barrier properties, the packaging manufacturers must determine a functional solution.

A critical aspect of food packaging, food products have a tendency to absorb surrounding aromas even when their packaging has not yet been opened. During prototyping, manufacturers must find a suitable material that will contain the food product’s aroma as well as protect the product from outside contamination.

Without the package prototyping phase in the packaging process, product owners may discover discrepancies with the packaging material only after large manufacturing runs have been completed and the product distributed. Once end users receive products in subpar packaging, the company risks losing loyal customers as well as revenue.   

3. Packaging That is Non-Biodegradable

In recent years, society has seen a major shift toward biodegradable, eco-friendly packaging that minimizes CO₂ emissions (as well as other byproducts and chemicals), product waste, and space in a landfill. With recent discoveries in the biodegradability of certain packaging materials, manufacturers can now use plastic packaging that takes less time to biodegrade than traditional packaging. During prototyping, packaging manufacturers can determine if biodegradable materials will meet the product’s specifications.

Currently, the initial cost of biodegradable materials can be more than the cost of non-biodegradable materials. However, non-biodegradables have subliminal costs, which include the long-term task of removing harmful toxins that are released from landfills. Over time, as biodegradable materials increase in demand, costs will decrease and eventually counteract their eco-unfriendly opposites.

4. Packaging with no Appeal

The printing and design of product packaging play significant roles in a consumer’s decision to buy. Many, maybe most, shoppers base their purchases on the outward appearance of the product. The physical look of packaging is a key player in marketing the product. Packaging with no marketing appeal will remain on the retail shelves, totally ignored, a waste of an investment.

Successful packaging stands out above the competition. Packaging prototypes with a unique design, attractive colors, and eye-catching details call out to shoppers and help solidify a sale. The prototype stage will help showcase the packaging’s marketing appeal, if it’s there, or make it apparent that it’s not, whichever the case.

These common problems during packaging prototyping can incur costly mistakes. Choosing the right packaging before moving forward with large manufacturing runs can result in significant savings. Have you considered the benefits of flexible packaging?

Download our ebook to find out if flexible packaging is right for your product’s specifications.  



How to Determine the Right Packaging for Your Product

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packaging process

How to Determine the Right Packaging for Your Product

The packaging process can be overwhelming, especially for first-time clients with a brand new product that’s ready for packaging. How can you tell what style of packaging fits your product? What materials do you need? What challenges will you face as you begin the search for high-quality packaging?

We’ve compiled a list of questions to make the beginning stages of packaging manufacturing easier for our clients. Your answers to these questions simply help us better understand your situation and what kind of packaging you need. We can then supply you with an accurate quote and begin the packaging process as quickly as possible.

We’ve also included frequently asked questions that we’ve collected from our previous packaging projects, accompanied with the answers, to help you better understand what to expect. Last, you’ll learn the benefits of flexible packaging, as well as all frequently used abbreviations spelled out accordingly.

Take me to the Questionnaire!

As always, we strive to make the packaging process as easy and straightforward as possible for all our clients. We are excited to learn about your product and talk about design, prototypes, printing options, and so much more.

If you need further assistance, a packaging quote, or would like to talk to a representative, call 315.226.1000 or contact us anytime. We’d love to hear from you and learn about your product! 

Maco Pkg Partners with Dow to Bring PacXpert to North America

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Maco Pkg Partners with Dow to Bring PacXpert to North America


Newark, NY – Maco Pkg is partnering with The Dow Chemical Company (NYSE: Dow) to manufacture PacXpert™ Technologies—an innovative form of flexible packaging that is changing the landscape for retail shelves and wholesale packaging.  The partnership will address the growing demand for convenient and sustainable packaging solutions in North America.

Maco Pkg ran several trials on various materials and packaging for Dow during the past six months—the  most significant being PacXpert.

“It’s a very stable pouch, very strong, especially in regards to all the testing it’s gone through,” commented Maco Pkg account executive Tom Seymour. “Because of the placement of the seals and angles on the packaging, consumers and manufacturers don’t have to worry about pouches bursting or breaking. It’s a huge advancement.”

With its unique ergonomics, PacXpert has earned multiple awards for its engineering design while enabling the transition from rigid, large volume containers.  This flexible pouch offers lightweight durability, optimized marketing space, and more efficient use of resources throughout the product lifecycle.

According to a Dow case study on sustainability, “The environmental impact of transporting one-gallon PacXpert containers is approximately 20x lower than the transport of other one-gallon containers.”

PacXpert comes equipped with handles on both the top and bottom for easy lifting and precision pouring. For shipping and storage, the pouch lays perfectly flat, optimizing shelf space. When filled with product, the packaging cubes out to allow for space-efficient storage, stacking, attractive shelf appeal, and the ability to stand up either horizontally or vertically. 

 PacXpertThe packaging fitment can be interchanged for a wide variety of possible contents, ranging from non-edibles (i.e. paint, motor oil, cleaning products) to edibles (i.e. breakfast cereal, dog food, coffee). Since the packaging is transparent, the contents are easily viewed, and printing options for all four sides are virtually endless.

For more information visit or

About Maco Pkg

Maco Pkg of Newark, NY has manufactured innovative, high quality packaging for a wide variety of industries for over 80 years. Within their 240,000-square-foot facility, they specialize in flexible packaging, contract packaging, and customized packaging solutions. Maco has serviced the US Military, food and beverage, industrial, automotive, medical and dental, health and beauty, electronics, and photography markets.

As an ISO 9001:2008, SQF 2000 Level 3 certified facility, Maco Pkg converts roll stock into pouches, film bags, standup pouches, side gusset bags, sheets, flexible packaging, speciality items, and much more. Maco Pkg is capable of packaging kosher and Oregon Tilth Organic certified products, and is FDA compliant. Maco’s services include consultations, prototype packaging, package manufacturing, sourcing packaging materials, trials and samples, and large runs.

Maco Pkg is committed to preserving the environment and works closely with biodegradable material suppliers to manufacture eco-friendly products. For more information, please contact Tom Seymour at Maco Pkg:; phone: (315) 226-1028, or go to   

About Dow

Dow (NYSE: DOW) combines the power of science and technology to passionately innovate what is essential to human progress. The Company is driving innovations that extract value from material, polymer, chemical and biological science to help address many of the world’s most challenging problems such as the need for clean water, clean energy generation and conservation, and increasing agricultural productivity.

Dow’s integrated, market-driven, industry-leading portfolio of specialty chemical, advanced materials, agrosciences and plastics businesses delivers a broad range of technology-based products and solutions to customers in approximately 180 countries and in high-growth sectors such as packaging, electronics, water, coatings and agriculture. In 2015, Dow had annual sales of nearly $49 billion and employed approximately 49,500 people worldwide.

The Company’s more than 6,000 product families are manufactured at 179 sites in 35 countries across the globe. On June 1, 2016, Dow became the 100 percent owner of Dow Corning Corporation’s silicones business, a global company with sales of greater than $4.5 billion in 2015, 25 manufacturing sites in 9 countries and approximately 10,000 employees worldwide. References to “Dow” or the “Company” mean The Dow Chemical Company and its consolidated subsidiaries unless otherwise expressly noted. More information about Dow can be found at



“Maco Pkg was our Ideal Packager” ~ Crown Maple

By | Uncategorized | No Comments

About a year ago, we needed a co-packer for a new project we were starting, a specialized line of single serve packets for maple sugar and maple syrup. Since they’re unique in the industry, we needed a co-packer company that could accommodate our specific needs.

Maco pkg was the ideal choice as a packaging company for us since they can maintain organic certification, cooperate with our unique needs, and work within our budget.

A major obstacle we had to overcome was the tendency maple syrup has to absorb surrounding odors very easily. Maco resolved all issues with the packaging material to maintain the quality and taste of our product. If there was an obstacle during the packaging process, Maco worked diligently to overcome it.

We had an elegant design for the artwork and Maco executed it well – we’re extremely happy with it. We were also positively impressed during our tour of Maco’s facility. They have a wide range of capabilities and the flexibility to work with customers for unique packaging. We’d recommend Maco on their excellent customer service and their ability to accommodate special needs.

We hope to do more packaging with Maco PKG in the future. They did an exceptional job and we are quite pleased.

A Powerful Product Receives Powerful Packaging

By | flexible packaging | No Comments
packaging company

Badass Power Cookie

When the Badass Power Cookie was first created, corporate owners were not convinced this nutritious yet delicious seaweed-baked cookie could survive in retail.

How Can a Cookie Pack a Punch?

Because the cookie contains spirulina, a blue-green algae filled with vitamins and nutrients, it has a bright, emerald green color – a factor that could deter potential buyers. The product needed packaging that could restore its aesthetic and visual appeal. The CEO conducted extensive research to find a packaging company that was attentive to specific needs and details. 

Local Packaging Company Offers Barrier Packaging

packaging company


Eventually she met a local food packaging company, Maco PKG, who she found to be personable and extremely helpful. Maco PKG is responsible for the cookie’s Superhero foil packaging. This food packaging company provided not only the essential (and attractive) foil packaging, but also valuable contact information that helped the power cookie establish a place in retail. 

The Badass Power Cookie can now be purchased online and in select food markets. As they seek to extend the line of flavors, the manufacturers are already brainstorming how Maco pkg will customize additional packaging for them (maybe even additional flavors).


Why Flexible Packaging is Clearing the Shelves

By | flexible packaging | No Comments
flexible packaging

Stand-Up Pouches | Flexible Packaging

Why does flexible packaging continue to overwhelm the packing industry? Several key factors have played a significant role in the rising level of popularity for flexible packaging since it first hit the market.

Flexible vs. Rigid Packaging

This innovative type of packaging provides an economical alternative to traditional rigid packing. Using only 25% of the plastic used for its rigid counterpart, it weighs 70% less than rigid containers. Most product owners find that it’s easy and affordable to ship both domestically and overseas. It also provides more options for design, including the stand-up feature that offers eye-catching print options, billboard effect marketing, great product appeal, and space management.

Does Flexible Packaging Really Protect your Product?

flexible packaging

Barrier Bags | Flexible Packaging

Flexible packaging often uses film to provide a barrier against light (such as UV rays from the sun), grease, contamination, and most importantly, moisture and oxygen. Each of the barrier layers is specially selected based on your product’s physical characteristics. When manufacturers design for high barrier, they calculate the OTR (Oxygen Transfer Rate) and MVTR (Moisture Vapor Transmission Rate). The OTR & MVTR determines the amount of air or moisture that transfers through a designated section of film/material within 24 hours. A high rating ensures that the product is able to withstand a variety of stressors and gives it shelf stability.

For Example …
The most ideal barrier packaging has an OTR & MVTR that is extremely low (0.0005), which allows little oxygen and moisture to pass through for any amount of time (foil is a great example). It protects your product from contamination and impurities.


flexible packaging

Foil Barrier Packaging | Maco PKG

In the past, most plastic packaging materials have not been able to decompose. But scientists have recently discovered a way to introduce an additive to the polymers used for flexible and rigid packaging to allow them to biodegrade. The additive prompts the decomposition to begin once the materials are exposed to a high microbial count (like that found in a landfill). The materials are reduced to water and carbon. This process typically occurs 18 months after exposure. The science behind this allows for similar barrier properties and shelf life and stability. The innovation in this arena continues to grow and will be the choice for packaging today and into the future.

Are you Ready to Try Flexible Packaging?

Is flexible packaging a viable option for your product? We can design packaging that suits your product’s temperature requirements, sizing recommendations, certification standards, and

barrier properties. Let’s find out if flexible packaging is a logical option for you – feel free to call +1-315-226-1000 and talk with a packaging specialist! 

Organic Packaging Part II; Exceeding Standards to Support your Organic Declaration

By | Organic packaging | No Comments

Last article we set the scene for organic packaging, explaining what it means and the importance of following official standards. Now we’re going to discuss the different aspects of packaging for organic food so that you know what to expect when you’re ready to package your organic package.

What Should You Consider When Evaluating Organic Packaging?

Organic Packaging

Organic Packaging

Flexible packaging offers solutions that demonstrate the uniqueness and saleability of the product. The package must contain and preserve a certain quantity of product as efficiently as possible. The contents may be measured by volume, by weight or by number. The information on the label must be correct and conform to the legal requirements according to the FDA.

You also need to consider various shapes and dimensions of the package. The package must protect its contents from external threats including spoilage, breakage, and damage from external environmental conditions (including tampering). Primary, secondary and tertiary packaging must be designed so that the product stays in perfect condition until it reaches the end user. The package must be strong and durable enough to protect the product with a reasonable safety margin.

Introducing Cutting-Edge Biodegradable Materials

Packaging should act as a primary marketing tool for the product, promoting the item at the point of sale. Flexible packaging offers a smaller carbon footprint and can create a billboarding effect on store shelves.

Due to technological advances in polymer additives, today’s market now offers new age, biodegradable materials. These packaging options offer the end user and producer the unique benefit of utilizing materials that support the core principles of organic sustainability.

The package must also attract first-time buyers and build brand loyalty for repeat sales. Combining multiple methods directly impacts the products effectiveness as well as support the claim of being an organic product.

What Should You Ask about Packaging for your Organic Product? You can find the right packaging partners by asking the following questions:
1. Is the facility Certified Organic?
2. Do they hold an Organic License to run products and/or packaging?
3. Who is their accrediting body?

Organic Packaging

Organic Packaging

4. Do they follow good manufacturing and handling practices?
5. Can your product be handled/filled/packed by machine?
6. What are the physical properties of your product?
7. Could the product be modified for easier packing without affecting its taste or character?
8. Are there detailed mechanical and technical specifications for every element of packaging?
9. Do the specifications comply with the machine requirements?
10. What certification does my vendor hold and how do they differentiate suppliers?

We welcome your questions! Give us a call at +1-315-226-1000 and let’s chat about your organic packaging options!

request a quote now! click here