High-Barrier Flat Pouches for Electrolyte Energy Gels

Electrolyte-rich energy gels with sodium, potassium, and mineral inclusions require packaging with superior barrier performance to maintain formula stability and prevent flavor drift over extended shelf life. Our specialized PET/AL/PE laminate flat pouches create an absolute oxygen and moisture barrier, protecting sensitive electrolyte blends from degradation during warehouse storage and outdoor race-day conditions.

The slim 3-side seal format fits easily into hydration vest pockets and cycling jersey compartments, while the tear-notch or micro-perforated tear line ensures quick access mid-activity. The water-resistant soft-matte exterior supports clean, clinical branding with electrolyte panels, hydration guidance, and heat-index usage callouts that remain legible under bright event lighting.

Key Points

• PET/AL/PE laminate for maximum oxygen and moisture barrier
• Slim flat format for hydration vest and jersey pockets
• Tear-notch access for mid-activity consumption
• Protects electrolyte formulas from flavor drift
• Ideal for sodium, potassium, and mineral gel lines
• Custom printing available from 200 pcs

Typical Structure

• PET / PE (standard)
• PET / VMPET / PE (enhanced barrier)
• PET / AL / PE (high barrier for electrolyte and functional gels)

Sizes We Commonly Produce

• 30g / 32g (1 oz)
• 40g / 60ml (2 fl oz)
• 90g / 100ml
• Custom sizes available based on your fill volume

Closure Options

• Tear notch
• Corner or center spout with screw cap
• Resealable zipper (multi-pack formats)

Lead Time

• Production: 10–15 days
• Delivery: 7–14 working days (DDP available)