2026 Agenda

Pouch Digitalization: Evolving Strategies for Converters

Digital print in flexible packaging is often characterized as a niche solution—best suited for short runs and small brands—while conventional technologies such as flexo are viewed as the long-term foundation of the industry. This perspective may be incomplete.

Rather than focusing on technology in isolation, this session will examine the underlying economic and operational assumptions that shape how digital and analog print are positioned today. In particular, it will explore whether commonly cited “crossover points” and use-case limitations are inherent to the technologies themselves—or a result of how converting businesses are structured, priced, and managed.

The discussion will challenge several prevailing beliefs:

• That digital print is structurally limited to short runs
• That analog and digital compete along a fixed cost curve
• That scale and centralization are required to optimize manufacturing

By reframing digital print through the lens of capacity utilization, margin generation, and local decision-making, the session will present an alternative view of where and how digital technology creates value. The session will conclude with perspectives on emerging operating models for converters—and whether the future of flexible packaging may be less about technology selection, and more about how production systems are designed and deployed.

The State of Flexible Packaging

Many factors related to packaging continue to challenge producers of consumer packaged goods (CPGs), with regulatory oversight and sustainability concerns at the top of the list. During this session, Dan Felton, president & CEO of the Flexible Packaging Association (FPA), will offer a fast-paced update on the state of the U.S. flexible packaging industry, including state and federal policy issues.

FPA Achievement Award Winner: Skippy Peanut Butter Squeeze Pack

A 2026 Flexible Packaging Association Silver Award Winner in the Expanding the Use of Flexible Packaging category, this Squeeze Pack from TOPPAN Packaging Americas, was developed for the Hormel Foods Skippy® peanut butter brand. This pouch revolutionizes peanut butter packaging with material innovation, on-the-go convenience, and eye-catching shelf appeal. The pouch design offers easy, practical, mess-free, dispensing. Crafted with a flex-crack-resistant barrier film, it delivers extended shelf life and durability. The compact, ergonomic format stands out among traditional peanut butter jars, combining functionality and aesthetic appeal. This Innovation Spotlight will also examine why pouches are uniquely positioned to solve today’s converging challenges around consumer affordability, sustainability goals, and regulatory compliance across food and non-food applications, while also delivering convenience for the consumer and a growth platform for brands.

Market Potential of Cast MDO Films for Mono-material Packaging Solutions

This session will explore how cast MDO technology can support recycling guidelines while helping reduce production costs for MDO films. Attendees will also gain insight into the key differences between cast PE MDO solutions and blown film technology, including how the two approaches compare in performance, processing, and application opportunities.

Evaluating Regulatory Consistency of Post Consumer Recycled Content for Food-Grade Applications

Rising demand for sustainable packaging that also meets strict food-safety rules has put a spotlight on how reliably post-consumer recycled (PCR) resins can be produced and validated for FDA compliance. Charter Next Generation (CNG), working with SGS and participating customers, is running a multi-phase study to evaluate FDA-compliant PCR films as a pathway to more circular packaging. The project compares PCR resins from multiple suppliers and manufacturing sites, measuring batch-to-batch variability and production efficiency through detailed analytical testing. A key focus is benchmarking recycled materials that have FDA No Objection Letters (NOLs) against non-FDA recycled inputs to assess how well different reprocessing and purification approaches achieve required safety levels. SGS contributes scientific oversight, including protocol design and migration testing, to confirm film performance stays within regulatory thresholds. The findings are intended to help brand owners and converters adopt food-grade PCR films with greater confidence and scale compliant PCR options faster

Advanced Whole Flexible Pouch Oxygen & Water Vapor Inspection

As brands accelerate the shift to sustainable packaging and next-generation barrier coatings, protecting brand integrity, product freshness, and shelf life begins with whole-package integrity. Leading inspection systems now go beyond film-only analysis, enabling whole-pouch oxygen and water-vapor permeation testing that mirrors real-world performance. Manufacturers can measure OTR and WVTR on fully formed packages, exposing barrier weak spots, seal imperfections, and environmental-stress effects that flat-film tests often miss. Sustainable structures such as coated paperboard add permeability complications like edge diffusion, so accurate results may require masking and controlled sealing. Paired with whole-package oxygen and moisture profiling, these approaches validate water-based coatings, biodegradable barriers, and lightweight laminates designed to reduce environmental impact. With higher consumer expectations, tighter regulatory scrutiny, and demand for longer stability, whole-pouch inspection helps packaging, R&D, and QA teams identify risks faster, optimize materials, and confirm performance—making it the emerging industry benchmark for barrier verification in modern flexible packaging.

FPA Achievement Award Winner: Pouch3 Cube Packaging

This session will explore the evolution of packaging formats and the inspiration behind the POUCH3 format, highlighting its relevance in today’s market. Attendees will gain insight through comparative case studies showcasing brands such as Lake Michigan Coffee and Elementary Pet Food that successfully transitioned from traditional formats to POUCH3. The discussion will also examine the cost-saving potential of adopting POUCH3, along with its environmental advantages. In particular, the session will address how Extended Producer Responsibility (EPR) mandates are shaping packaging decisions and how POUCH3 can help companies meet sustainability goals while remaining cost-effective.

Converter's Perspective

Driving Sustainability in Flexible Packaging

While Flexible packaging is the fastest growing packaging format in North America, it faces challenges for being difficult to recycle.  By itself, flexible packaging is the most sustainable packaging format in terms of greenhouse gas emissions, however that is only one piece of the puzzle.  This article explores key principles of circularity, extended producer responsibility (EPR), and material innovation driving change. It highlights environmental benefits, such as reduced carbon emissions and energy use, and examines financial incentives under EPR policies. Market trends indicate growing adoption of mono-material solutions and post-consumer recycled content. By aligning technology, policy, and design, flexible packaging can deliver low-impact solutions that enable brand owners and converters to meet sustainability goals while maintaining performance and cost efficiency.

Converter's Perspective

Convenience and On-the-Go -- Why Compostable Packaging Is the Solution

Convenience and on-the-go consumption are driving pouch growth while exposing the limits of traditional end-of-life solutions. Small formats and food contamination often make recycling ineffective in real-world use. In this educational session, Rodrigo Castaneda, VP & GM North America at TIPA, shares why certified compostable packaging is a practical solution for convenience-driven applications. He covers the key factors influencing brand adoption, including performance, barrier requirements, machinability on existing equipment, and investment considerations.

Attendees will gain actionable insights into how compostable pouches are being implemented today through collaboration across the market, improving manufacturing efficiency, and aligning packaging with real consumer disposal behavior.

Converter's Perspective

Developing, Scaling, and Validating Monomaterial Pouches for a Circular Economy

This presentation explores how flexible packaging converters are advancing fully recyclable monomaterial pouch structures using PE- and PP-based systems. It highlights efforts to balance recyclability, performance, and manufacturability across applications such as snacks, granola, confections, and retort pet food. The session also examines the role of material innovation, film design, and converting processes in scaling these solutions. Attendees will learn about technical challenges, sustainability and EPR implications, and the future innovation pipeline for high-performance recyclable flexible packaging.

2026 Steve Fairfield Memorial Award for Flexible Packaging Innovation

AeroFlexx’s Mono-Material Liquid Packaging Technology: Balancing Flexibility and Functionality

This presentation explores the breakthrough technology behind AeroFlexx’s mono-material packaging innovation, highlighting how it balances performance and sustainability and provides flexibility without compromising functionality. Attendees will gain insights into material innovations, design strategies, and real-world applications. The session will also showcase how AeroFlexx addresses industry challenges such as enhancing consumer convenience, improving supply chain efficiency, and expanding sustainability while maintaining a reliable packaging experience.

A Flexible Packaging Roadmap to Navigating Extended Producer Responsibility

The 2026 Global Pouch Forum will begin with a timely keynote panel discussion on the current state of Extended Producer Responsibility (EPR) for flexible packaging. To minimize fee implications, converters of flexible packaging materials and consumer packaged goods (CPG) brand owners using those materials need to prepare for the requirements of EPR programs now in various stages of implementation, mapping out a clear “end-of-life plan” for the materials. Valuable takeaways from this roadmap to EPR success will include:

• An understanding of where the seven EPR states are all in their phases of implementation, including reporting timelines and expectations
• Challenges for flexible packaging, including severe and pressing issues with California’s program
• How regulators will start increasing enforcement activity—but litigation remains a big question mark
• The importance of early engagement with Producer Responsibility Organizations (PROs)
• The role of recycling technologies in creating circular packaging solutions
• Balancing near-term compliance obligations with long-term sustainability investments and innovation

Innovation Spotlight:

PCR Resin Use in Potato Bag Packaging

Emerald Packaging recently gained recognition via the Flexible Packaging Association Achievement Awards for its new 30% Food Contact Post-Consumer Recycled (PCR) Resin for 5 lbs. and 10 lbs. Potato Bags, winning awards for Packaging Excellence and Technical Innovation. Emerald Packaging’s shift toward PCR directly supports the sustainability goals of many of its food industry partners. Most recently, Emerald Packaging partnered with Idaho Package, Wada Farms, and Walmart to introduce the first 30% food contact PCR bag for the potato category. This project pushed the limits of PCR, given the exacting standards potato bags must meet, like impact resistance. This initiative aligns with Walmart’s Project Gigaton, targeting a one billion metric ton emission reduction by 2030. To date, Walmart has eliminated more than 200,000 pounds of virgin plastic in its potato packaging.

Sunset Beach Bash

A perfect kickoff to the Global Pouch Forum—relax with drinks and light bites, enjoy oceanfront views as the sun sets, and network with fellow attendees, speakers, and sponsors before the conference starts.

Morning Yoga

Start the morning feeling refreshed and energized with a welcoming yoga session featuring gentle movement, stretching, and mindful breathing. Open to all levels, it is a great way to recharge before the day begins.