SunDance installs XL-DR pouching machine for stand-up pouches, side gusset bags, bag-in-bag formats

USA – SunDance has installed an XL-DR pouching machine, supplied by SunCentre USA, to produce standard stand-up pouches, registered gussets, inserted side gusset pouches, terminated and non-terminated side gusset bags, and bag-in-bag formats with a range of closures, expanding its internal flexible packaging capacity.

SunDance began offering flexible packaging in February 2020 and has since expanded its range with additional material, lamination, finishing, and closure choices including POUCH³, MagneClose, and spouts. 

The new equipment was supplied by SunCentre USA, an Illinois-based manufacturer of machinery used for pouch production, pour spout insertion, and precision slitting.

The POUCH³ Advantage

Patented by Sun Centre, the POUCH³ is designed to use 30 to 40 percent less material than a standard stand-up pouch. 

A standard stand-up pouch uses a bottom gusset that adds material and weight; POUCH³ achieves stability through a different structural design that reduces film consumption. 

For a brand packaging 1 million pouches annually, a 35 percent material reduction translates directly into lower film costs, reduced shipping weight, and less packaging waste. 

SunDance manufactures the pouches on in-line machinery built by Sun Centre and can run them across several material structures, including sustainable options.

A Growing Flexible Packaging Portfolio

The XL-DR machine’s capability to produce bag-in-bag formats (a smaller pouch inside a larger outer pouch) is used for portion-control applications such as single-serve condiments inside a bulk carton, or for moisture-sensitive products where the inner pouch remains sealed until use while the outer pouch provides branding space. 

Terminated and non-terminated side gusset bags refer to whether the gusset folds are sealed (terminated) or left open (non-terminated) at the top, affecting how the bag stands and how it is filled. 

SunDance president JohnHenry Ruggieri explained that SunDance has been at the forefront of advances in flexible packaging and flexible pouches for more than six years, understanding the intense competition clients face every day and committing to offering the widest array of packaging options to support their product marketing and sales objectives with industry-leading turnaround times.

Tailored Solutions for 2026

SunDance and Sun Centre have expanded their ability to supply POUCH³ for customers looking for different packaging formats and production efficiencies. 

The company is working with clients on tailored uses of POUCH³ for 2026 packaging marketing plans. 

For a brand launching a new product line, the ability to switch from a standard pouch to a POUCH³ reduces time-to-market by eliminating the need to requalify the package on existing filling lines, as the material reduction does not change seal dimensions or filling interface.

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