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Popcorn Packaging

A family group shot of all the different types of Custom Popcorn packaging Carepac offers Custom Printed Heat Seal Snack Food Packaging Back Sealed Popcorn Packing Snack Food Bags Popcorn Bag

Custom Printed Popcorn Packaging to Beat the Competition

Popcorn is one of the most popular snacks in the United States. It's been enjoyed by humans for hundreds of years. In fact, scientists have found evidence of popcorn in 1,000 year old peruvian tombs. Popcorn first became an American staple in the late 1890's when an entrepreneur from Chicago invented the first popcorn-popping machine. Nowadays, popcorn, both in kernel form or fully-popped, is found in the snack aisles of supermarkets and other retail outlets across the country. 

CarePac specializes in using high-quality flexible barrier film to create custom packaging for your popcorn products. Popcorn is considered a healthy snack, full of flavor and fiber. The last thing customers want is popcorn that's chewy and stale. Protecting your product from moisture and oxygen is what keeps your corn fresh and crunchy. We know how to layer different barrier films to create airtight packaging that locks in flavor and extends the shelf life of your popcorn so it's ready for your customers to enjoy. 

Everything You Need to Know About Our
Flexible Frozen Food Packaging

Custom Stand Up Pouch Packaging Flexible Recyclable Stand Up Pouches with Window

Stand Up

The stand up pouch is the most popular flexible barrier configuration we make. These bags are outfitted with a bottom gusset, that when deployed, allows the pouch to "stand up" on a shelf in a store. Add features such as a zipper closure and a tear notch for extra convenience. This pouch is great for both kernels and fully popped corn.

Custom Printed Back Seal Pillow Pouch Popcorn Packaging Plastic Bag


With a 3 seal pouch configuration, you load the the popcorn in the same way your customer would remove it - through the top. Additionally, bags with a zipper closure could be used without heat-sealing. 3 seal pouches pack well in standard cardboard boxes, saving you money when shipping your product to retailers.

Printed Glossy Popcorn Pouch Aluminum Foil Pillow Pouch


Save money on your Pillow Pouch tubing and roll stock with CarePac. Our tubing and VFFS roll stock is compatible with most filling and loading machines. But unlike your machine maker, we focus only on the consumables, so our pricing can be substantially better than theirs. 

Popcorn Packaging Designed
for Top-Shelf Product

CarePac understands the needs of small and medium-sized popcorn distributors. Our custom packaging offers a professional appearance — like the packaging used by Fortune 500 companies.

We Save You

From pre-formed pouches to tubing and roll stock for form fill machines, we save our customers money every day on their popcorn packaging needs. 


We offer some of the fastest packaging lead times in the business. Expedited lead times for digital and plate printing come in at 4 weeks and 5 weeks respectively. 


Packaging your popcorn in flexible barrier packaging keeps your popcorn fresher for longer, and makes storage simple for your customer.

Low Minimum Order Quantities

Digital prototyping and test runs are available with full production runs from 5,000 popcorn bags.

Art & Design

Need a logo or design? No problem! We provide brand design services to help you create the branded custom packaging your product deserves. We'll get your product to stand out from the crowd!

FDA Approved & Kosher

All our packaging for popcorn is FDA approved, Kosher, TSE free, BPA free, and Sulfer & Phthalates free.

Avoid the
China Trap 

Purchasing pouches from China does not provide cheaper or faster alternatives, like many small and medium sized businesses have been made to believe. In fact, many of our current clients have encountered problems when ordering from China due to the language barrier, the lack of compliance documentation, longer lead times and, above all, higher tariffs.

From Popcorn Kernals
to Kettle Corn

Heat Seal Printed Laminated 3 Side Seal Bag Popcorn Packaging

Popping Corn

Gourmet popping corn needs quality high impact packaging to get noticed and SELL. While popping corn is a naturally preserved product, the presentation of it to the consumer is extremely important. Flexible pouches save your company money over hard sided jars.

Aluminum Foil Stand Up Pouch for Popcorn Resealable Pouch with Ziplock

Popcorn Snacks

Popcorn is a grown snack food segment. But you need to your packaging to do a few things if you plan to grown. First, maintain freshness and shelf-life. Second, show off your brand so customers choose your pop corn over the competition. 

Popcorn Packaging Kettle Corn Pillow Pouch Gourmet Kettle Corn Popcorn Resealable Treat Bag

Kettle Corn

Kettle Corn has unique moisture vapor transmission requirements. Soggy, or overly dried out Kettle corn won't make for happy customers, and if you're shelf-life is too short, you'll have endless supply chain problems. Luckily CarePac's got you covered.  

Custom Flexible Barrier
Film Packaging

Here are some of the configurations available for custom food packaging.

Stock options can offer typical unit sizes for your food packaging, however, if you find your
company’s needs are different than stock sizes, flexible barrier packaging allows for creating
the size best suited to your needs.

Puffed Food Packaging Bag Popcorn Snack Moisture proof Plastic Stand Up Zipper Pouch & Puffed Food Pouch

Choosing the Right Flexible
Barrier Popcorn Bags

Flexible barrier packaging is a great solution for preserving the freshness of your popcorn products.

There are certain considerations that should be taken into account when deciding on the right type of barrier packaging bags for your popcorn. How long is your product going to be in the package? What is the required shelf life? How important is the freshness of your product?

Stand up bags offer many unique benefits over traditional popcorn packaging containers. First let's look at convenience. Customers want a package that easy to open and reseal to keep their favorite snack fresh. Configuring your flexible popcorn containers with a tear notch coupled with a recloseable zipper gives the end-user the best of both worlds. Plus, as a manufacturer,  you get to save costs. Pouches and bags are flexible and lightweight - you can pack more items into a shipping container and less weight equals savings on shipping costs.

Think about these questions as you consider your packaging needs:

  • Where will my product be sold?
  • Are there space constraints, or retail requirements?
  • How much product do you need in each pouch?
  • Will the product be stored on a Shelf? Does it need a hang hole?
  • How is it transported? Air freight is subjected to higher pressures than truck shipments.
  • What is your "fill philosophy" - how much product do you want in the packaging?
  • Is your product single-use or multi-use?

These are just some of the questions our packaging specialists will walk you through as we prepare to create your custom flexible barrier packaging. We are here to serve!

Popcorn Packaging FAQs

Whether you are new to custom printed packaging or a seasoned pro you may have a few questions about our products and process.

Q: Do you offer wholesale pricing when buying popcorn packaging in bulk?

Yes, with CarePac you can save even more with our everyday, wholesale pricing available on our stock bags.

Q: Do you offer custom sized popcorn bags?

Looking for a more specific pouch size for your popcorn packaging needs? We have got you covered. We have come to understand that sometimes our clients are looking for something more specific in their bags. A specific size or configuration – that is why we offer custom-sized bags to meet these needs. We make it fast and easy. We make them so you can even use your artwork and designs. Whether you need food-grade custom pouches, or tamper-evident packaging, we’ve got you covered. 

Q: Can I print my own design on my custom popcorn packaging?

Depending on your needs and preference, we offer custom printing both digitally and with the use of plates. While digitally printed bags come with several advantages, we sometimes advise clients to opt for plate printing depending on their needs. Mostly because plates offer the lowest per-bag price points. However, digital prints offer a more robust color count and are its best for short run usage. Whichever the case, we always have a support staff to walk you through the production process and help you identify which printing is best for your project.

Q: What if I need help designing my popcorn packaging?

You don’t have to bring press-ready art. There are many technical considerations when printing barrier films, and we do all that work for you. We’ll take your original art files and set them up for printing to ensure you get the best quality printing and develop digital art proofs that you can revise. We focus on providing custom printed pouches and barrier packaging that meets your budget.

Q: What is the standard lead time on a custom printed popcorn bag?

In our industry, contrary to what you might think, a ten-week lead time is not uncommon. We offer the best lead-time options on all our food packaging quotes compared to other brands. CarePac's leadtime menu offers you control of the speed to cost ratio. With our fastest Leadtime being 15 working days. 

Q: How much do custom printed bags cost?

Check out our free online quick quote form to get a cost for your bags.

Q: What is your Minimum Order Quantity for printed popcorn bags?

Prototyping from a hundred bags, and on printed popcorn packaging bags and pouches we offer as low as 1,000 for digital and as low as 5,000 for plate printing. We strive to provide high quality printing services and materials in a low price.

Care Design™

Make Your Product Fly Off The Shelf With Custom Printed Pouches

When it comes to custom printed popcorn packaging - customers buy with their eyes first.

Great packaging can mean the difference between someone trying your product, or bypassing yours for a competitor’s.

And nothing pulls their focus more than attention-getting, custom printed packaging!

When you’re ready to design a custom printed bag, our experienced retail design consultants will help you create a look that will make your product SELL.

Overwhelmed with all the options?


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