There are only so many ways to package bulky items. But what makes this a more complicated question is that there are many unknown fit-for-use criteria that, as with any package development, must be taken into consideration in order to provide the right packaging for the individual application. Examples of questions that need to be considered include whether visibility of the product through the packaging is required; whether easy opening is necessary; what specifications are required for barrier, slip, and sealant; how the product is being filled, sealed, and sterilized; where and how will it be sold; how the package is opened and used or reused, disposed of, etc.

Aside from the specific fit-for-use needs there are several possibilities. Bags or pouches are always an option. A header is not always necessary; hang holds or a header can be formed into the top of a bag or pouch with a seal, or the pouch can be configured as a stand up with an easy tear-opening feature. Product instructions could either be printed on the bag or on an insert. There are several new square or box-style stand-up pouch formats that could have potential with easy-open features.

Depending on whether this is one rolled tube set or several pieces, another potential solution could be to use a folded paperboard liner that inserts into a bag. The paperboard would form the bottom and sides on the inside of the bag. This could provide a more cost-effective alternative to add rigidity to the bottom and sides. It also provides ease for filling and unpacking as the bag is held open by the paperboard - exhibiting functionality between a rigid tray and a bag. This structure also allows the top to be clear, and the visible side of the paperboard can be used for graphics and copy.

A last option is a vacuum-formed film laminated to a nonformable lidstock. Generally, these are supplied in roll form and run on a machine that heats the web to soften it and then pulls a vacuum to form the web into the right depth and shape for the product being packaged. The product is dropped into the vacuumed or formed portion, and a lidding film is sealed to the top. The lidding, or nonformable web, can be designed to be peeled from the formed web for easy access to the product.