Context and Objectives
Pharmateam Srl is an Italian company active in the nutraceutical sector, specializing in the production of energy bars and dietary supplements
Like many dynamic businesses operating in high-variability markets, Pharmateam faced a significant challenge: organizing the production of customized packaging with a scalable logic, capable of responding precisely both to market testing needs and large-scale launches
Traditionally, flexible packaging requires high print runs, long lead times, and non-negligible warehouse costs. For Pharmateam, this often meant being forced to order more packaging than necessary, increasing costs and generating unused stock
The main objective of the collaboration with Packstyle was twofold:
- ensure maximum production flexibility, through reduced batches on demand;
- reduce procurement times, in order to respond promptly to market demand
Added to this were other fundamental requirements:
- Food compliance and packaging safety;
- Preservation of the organoleptic and nutritional properties of the products;
- Compatibility with the packaging machinery already in use;
- Reduction of the logistical impact, thanks to the introduction of lighter and more compact packaging, particularly doypacks replacing rigid containers
Pharmateam was looking for a supplier capable of developing customized packaging, in rollstocks and bags, with small batches, quick turnaround times, and tangible operational benefits throughout the supply chain
Technical Challenges
The implementation of this strategy presented several operational criticalities
For the energy bar line, the company uses flow-pack machines, which require film on rollstocks with precise technical specifications: adequate thickness, controlled coefficient of friction, and good heat sealability. Finding a material that ensured optimal smoothness on the automatic lines, without compromising the product's protective barrier, was the first hurdle to overcome
In parallel, Pharmateam had to manage multiple product references (different flavors, different formulations), each with its own graphics and information
With traditional suppliers, this would have resulted in high costs and complexity due to separate printing plates/setups. The challenge was therefore to manage multiple graphics even on small batches, in a sustainable way. For the powdered supplement line, the company evaluated switching from rigid containers to stand-up pouches (doypacks). This upgrade involved new requirements:
- Introduction of resealable zip pouches to ensure content preservation after opening;
- Materials with high barriers against moisture and oxygen, to ensure the product's shelf-life;
- Versatile and functional formats, both for the packaged quantities (from single doses to a kilogram), and for shelf display.
- Reduction of transport and storage costs, improving handling efficiency and minimizing warehouse space occupied
Implemented Solutions
Project 1: Rollstocks for energy bars
Packstyle tackled the first project by supplying Pharmateam with high-resolution digitally printed flexible film rollstocks, ideal for the flow-pack packaging machines already in use.
Thanks to the digital and multi-graphic printing service, Pharmateam was able to order small batches – for example, 2,000 wrappers divided into 4 different graphics (500 per flavor) – within a single order. This approach eliminated the need for high minimum quantities for each reference and reduced the waste of unused printed material
During an initial testing phase, the technical teams of Packstyle and Pharmateam collaborated to identify the most suitable laminated structure, capable of offering the right mechanical performance and product protection
A high-barrier multilayer film, optimized for the company's automatic packaging lines, was selected. The tests confirmed the full compatibility of the material, meeting the technical needs that emerged during the initial testing phases. Each rollstock was accompanied by the required food certifications, as well as detailed technical specifications for the correct setting of sealing and cutting parameters. The printing quality ensured a vivid color rendering and perfect readability, even on small-sized wrappers
This system allowed Pharmateam to switch to a just-in-time production logic: the company now prints only what is needed for one or two months of production, updating graphics and nutritional claims with every reprint, with guaranteed delivery times (4, 7, or 10 working days)
"We needed a partner capable of revolutionizing the way we manage packaging, and Packstyle exceeded expectations," – Owner of Pharmateam
Project 2: Doypacks for Dietary Supplements
The second project concerned the design and supply of stand-up pouches for the powdered supplement line
Packstyle developed customized doypacks in terms of formats and graphics, using high-barrier multilayer materials – such as coupled aluminum or recyclable metallized film – to ensure effective protection against moisture, light, and oxygen. Each pouch was equipped with a resealable zip, to facilitate multi-dose use by the consumer, without loss of quality
The format of the pouches was calibrated based on the product type: from 30g single doses, to 250g packages, up to 1kg pouches
This flexibility allowed Pharmateam to propose the right balance between quantity, ergonomics, and aesthetics, while optimizing visual shelf impact. One of the main benefits was the positive impact on logistics. Compared to rigid containers, doypacks offer:
- Reduced storage volume when empty;
- Lower weight, resulting in a reduction in transport costs;
- Greater efficiency in palletized loads
As reported by independent industry analyses, the adoption of flexible packaging allows for a tangible reduction in logistics and transport costs, in addition to greater sustainability
"We solved technical compatibility problems on the packaging lines and reduced logistical costs by switching to flexible pouches," – Owner of Pharmateam.
Also from a production standpoint, integration was simple: Packstyle pouches can be filled manually or with semi-automatic machines, thanks to the precision of the dimensions and seals. Graphic customization transformed the packaging into a true communication tool, eliminating the need for additional labels. All regulatory and commercial information is printed directly on the pack, improving the perception of product quality. Pharmateam was able to order small batches of doypacks (a few thousand pieces per reference), aligning them with commercial launches without overproduction. In the case of seasonal promotions or last-minute releases, the packaging is ready in a few days, avoiding delays or stock-outs
"Thanks to Packstyle, today we can order even a few thousand pieces for each reference, receiving them within a few days.
This has resulted in an enormous benefit: no more excessive stocks or production stoppages." – Owner of Pharmateam
Results and Benefits
The collaboration between Pharmateam and Packstyle led to a significant transformation in packaging management, with concrete effects throughout the supply chain, both from an operational and strategic point of view
- Reducing waste and warehouse costs, producing only what is needed, when it is needed
- Accelerating time-to-market, with guaranteed deliveries in 4, 7, or 10 days
- Maintaining maximum print and material quality, even on small runs
- Optimizing logistics, thanks to lightweight, compact, and easily storable solution
- Managing multiple graphics in a single order, without additional setup costs
- Strengthening brand consistency, with packaging that combines aesthetics and functionality
The Pharmateam case highlights how packaging, from being a simple container, can become a strategic asset capable of supporting a company's agility and competitiveness
Through the combination of digital technology, technical know-how, and lean production capacity, Packstyle has made a new way of managing packaging possible: faster, customized, and more sustainable.