Custom Refill Pouches
A refill pouch has to transfer its contents into a bottle without spilling, and it has to make sense next to the hard pack it refills. The pouring geometry is the whole design.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the spout pouch structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures refill pouches actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
The refill has to hold exactly what the bottle holds
A refill that overfills the bottle leaves the customer holding a partly full pouch with an open spout, which is where the mess and the complaints come from. Match the fill to the bottle's usable volume, allowing for the headspace the bottle needs, and state the pairing clearly on the pack.
The mistake that costs a print run
A refill that looks like the lesser version
The refill is often the pack a repeat customer sees most, and treating it as an afterthought undercuts the brand they already bought into. Give it the same design attention as the primary pack, and use the space a pouch gives you for the instructions the bottle never had room for.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom refill pouches
What size refill pouch matches a 500 ml bottle?
A pouch around 5.5 × 9in with a 3in gusset holds roughly 500 ml. Match the fill to the bottle's usable volume rather than its stated capacity, so nothing is left over.
Does a refill need a spout?
For liquids going into a narrow neck, yes — pouring from a cut corner is where spills happen. Powders into a wide mouth manage without one.
Should the refill look like the original pack?
It should look like the same brand and carry the same care. Refills are what loyal customers buy repeatedly, so a visibly downgraded pack sends the wrong message.