Fox Packaging's Aaron Fox and Iliana Csanyi Discuss Measure of Performance in Pouch Bags

MCALLEN, TX - A normal topic in the hands of an expert becomes a fascinating gem. Packaging, for example, is an everyday aspect for our industry and consumers alike, but from the perspective of Fox Packaging’s passionate employees, I’m reminded how every step matters.

As Aaron Fox shared with me, seals need to hold through the cold chain, zippers have to align smoothly on high-speed equipment, and films must track consistently to avoid downtime. Once that pouch makes it to the store, durability against stacking, drops, and temperature swings becomes just as important as clarity and branding.

“When we talk about pouches, it’s easy to focus on film type alone, but the real measure of performance is how that pouch carries the product from line to shelf to home,” the company’s Vice President said.

Not only does the job need to be done, it needs to be done sustainably. The win, the Fox team reflected, is when sustainability and performance reinforce each other: gauges chosen to protect against product loss without adding unnecessary plastic, airflow features that help reduce shrink at retail, and end-of-life labeling that gives shoppers clear instructions through resin codes and How2Recycle.

“PFAS can persist in the environment and pose risks to human health. Removing them from our materials and processes is a concrete way we live our sustainability and social-responsibility commitments,” Iliana Csanyi, Sustainability Manager, commented.

Pouches matter, she shared unequivocally. But balancing ecological responsibility and all that they offer—shaping how produce is protected, presented, and experienced—can seemingly present a paradox.

“On the shelf, the stand-up format creates a clean, upright display that grabs attention, while reclose features reduce open-bag waste and make storage easier at home. Large panels provide space for certifications and traceability, giving shoppers confidence in what they’re buying,” Iliana continued. “Behind those benefits is a careful balance of materials. Today’s pouch formats are built primarily from mono-material poly films, LDPE (#4) and PP (#5). LDPE is more common in produce, offering reliable sealability and flexibility for hand-pack operations. PP brings a crisper structure and high clarity that performs well on automated lines.”

And in fresh produce, managing respiration and condensation becomes an additional variable, necessitating clear display windows, anti-fog, and ventilation tailored to the product.

So, what should companies be considering in pouch bags without losing performance?

“Sustainability in pouches starts with keeping the design as simple as possible,” Aaron said.

Choosing mono-material formats, LDPE (#4) or PP (#5), makes recovery more straightforward, provided the zipper, label, and inks are compatible. LDPE often fits store drop-off programs, Fox’s experts said, while PP delivers better shelf clarity and automated performance, but currently has a more limited collection access.

“Grocery chains are moving away from PFAS due to water and health concerns, plus regulatory pressure. Our job as manufacturers is to partner closely and verify that these goals are actually met on the ground,” Aaron concluded.

It is partners like Fox Packaging who remind us that a pouch bag is more than an everyday item, carrying a deep responsibility. When performance, sustainability, and design align, a tool becomes a critical vehicle delivering the produce our industry has worked so hard to raise.