Sport Gels Packaging: How Are Energy Gel Pouches Made?

Sport Gels Packaging: How Are Energy Gel Pouches Made?

As the demand for convenient, performance-focused nutrition continues to grow, energy gels have become an essential tool for athletes and active consumers. These compact, fast-absorbing supplements require packaging that can match the speed, precision, and portability demanded by their users. ENFLEX, a Volpak brand, provides cutting-edge horizontal form-fill-seal (HFFS) technology designed specifically to address the unique requirements of this rapidly growing sector.

Energy Gels and the Role of Packaging

Energy gels are designed to be used during physical activity, delivering concentrated sources of carbohydrates, electrolytes, and other performance-enhancing ingredients. The packaging must ensure product integrity, allow for easy opening and consumption, and be portable enough to carry while running, cycling, or training. These demands make flexible pouching the optimal format.

How Are Energy Gel Pouches Made?

The Challenge: Precision and Hygiene

Due to the viscous nature of sport gels, dosing and sealing must be handled with extreme care. Spillage, under- or over-dosing, or improper sealing can compromise the product experience and brand trust. Additionally, since the product is consumed directly from the pouch, hygiene standards must be exceptionally high.

ENFLEX Solutions for Sport Gel Packaging

ENFLEX machines, such as the F-17 DX, are tailored to meet these challenges. Operating from a single reel of flexible material, the system forms, fills, and seals each pouch in a fully automated, compact solution. Key benefits include:

  • Accurate Dosing: Ensures consistency in product delivery, vital for maintaining dosage standards in nutraceuticals.

  • Hermetic Sealing: Preserves the product and protects it from external contaminants.

  • Compact Footprint: Ideal for facilities looking to maximize efficiency without sacrificing floor space.

  • Modular Integration: Allows for additional options such as printers, cameras, or labelers to be added based on production needs.

Designed for Versatility

The F-17 DX is capable of running in simplex or duplex mode, providing the flexibility to adapt output according to demand. It can also produce shaped pouches that not only enhance shelf appeal but also offer ergonomic benefits for on-the-go consumption.

ENFLEX machines are compatible with 100% recyclable materials, supporting sustainability goals while maintaining packaging performance.

Partnering for Performance

With its proven track record in pharmaceutical, healthcare, and personal care sectors, ENFLEX brings the same standards of hygiene, efficiency, and flexibility to the nutraceutical market. The ability to deliver high-precision packaging for viscous products like energy gels makes ENFLEX a trusted partner for sport nutrition brands seeking reliable, scalable pouching solutions.

Get in touch to learn how ENFLEX can power your packaging performance.

CONTACT US
Form

PRIVACY POLICY 

1. Controller

The company you’re trying to contact with this form (the “Company”) processes your personal data – in quality of Controller/Joint Controller – in accordance to the Privacy Policy to which you may refer for the purposes described below. Both of these processing are based upon the legitimate interests of both Coesia S.p.A. – the holding company of the Coesia group – and the Company. By ticking the box below, you also consent the Company to communicate and share your personal data to the other entities part of the Coesia group for the direct marketing purposes described below. Here below you can find the key info on the processings. 

2. Purposes

In particular, the Company processes the personal data you provide filling up the form, for the following purposes: 

a. collect identification and contact data for registering your attendance at the event organized by the Coesia/Company and/or reply to queries concerning the Coesia/Company activities and/or your contractual or pre-contractual relationships with Coesia and/or the Company; 

b. send to your email newsletters of informational, promotional and advertising nature and/or other materials for direct marketing purposes; 

c. analyze your interaction (“Insights Data”) to materials sent by the Company for marketing communication purposes above and create a profile to send you information based on your interests (“Profiling”). 

3. Legal Basis

The data processing under letter a. above is necessary for the performance of a contract or to take steps prior to entering into a contract between you and Coesia and/or the Company.  

The data processing under letters b. and c. is based on the legitimate interest of both the Company and Coesia S.p.A. to send you marketing communication and evaluate the Insight Data to set out marketing strategies and send you information based on your interests. 

4. Data sharing purpose

In accordance to the Privacy Policy and given your explicit consent, the Company may share your personal data with other companies of the Coesia group (“Coesia Entity/ies”, which act as Joint Controllers, jointly the Company) in order to allow the other Coesia Entities to send you marketing and commercial information, newsletters and/or materials and to process the Insight Data within Profiling (as specified under letters b. and c.). 

You can give your explicit consent to the data sharing for marketing purpose checking the following box. In this case, the profiling processing will be carried on the basis of the recipient Coesia Entity’s legitimate interest. 

It remains understood that in case of denial of giving your consent, the marketing and profiling processing will be carried out only by Coesia and by the Company based on their legitimate interests, as specified above. 

CAPTCHA
This question is for testing whether or not you are a human visitor and to prevent automated spam submissions.
1 + 0 =
Solve this simple math problem and enter the result. E.g. for 1+3, enter 4.
See all news The building blocks of at-home diagnostics: swab sticks, sample integrity, and packaging explained