The growing attention around tethered caps originates from the EU Single-Use Plastics Directive (EU) 2019/904, which states that:
“Single-use plastic items listed in Part C of the Annex, in particular beverage containers with a capacity of up to three litres, whose caps and lids are made of plastic, may only be placed on the market if the caps and lids remain attached to the containers during the intended use of the product.”
This sets a clear direction toward keeping packaging components connected throughout use. In this context, Gualapack has already developed three types of tethered caps that are industrially ready, available for customers who wish to adopt this solution proactively.
What are tethered caps?
A tethered cap is a closure that stays connected to the package after opening, preventing separation during use and disposal.
In flexible packaging, tethered caps are integrated into spouted pouch systems, where the cap is linked to the spout via a hinge or flexible tether.
Within the wider family of caps and spouts for flexible packaging, tethered caps are one of the clearest examples of how closure design can directly influence sustainability outcomes.
Why are tethered caps more sustainable?
In conventional beverage packaging, removable caps are functional but vulnerable to loss. Once detached, they are more likely to escape collection systems and contribute to litter—especially in on-the-go consumption or products used by children.
Tethered caps address this at the source.
They keep the cap with the pouch throughout the product’s lifecycle, without requiring consumers to change their habits.
For brand owners, this offers:
- Greater control over packaging integrity
- A tangible response to litter reduction
- A clear signal of environmental responsibility
For consumers, the experience remains intuitive and familiar.
Gualapack range of caps
Gualapack has included tethered caps in its portfolio reflecting a customer-centric approach, based on real market needs rather than minimum compliance.
Brand owners increasingly ask for:
- Packaging that anticipates future expectations
- Solutions that reduce redesign risk
- Sustainability features that are credible and functional
By developing tethered caps early, Gualapack enables customers to make proactive choices, rather than reactive ones.
How tethered caps work in flexible packaging
In spouted pouches, tethered caps are engineered as fully integrated closure systems.
They consist of:
- A spout welded to the pouch
- A cap connected via a flexible tether
- A closure geometry designed for secure resealing
The tether is designed to keep the cap attached while allowing it to open fully and stay clear of the dispensing area. When properly engineered, the tether becomes an almost invisible feature in everyday use.
From baby food to energy gels
Tethered caps are especially valuable for on-the-go consumption, making them ideal for products like energy gels or kids' snacks. The lanyard feature enhances convenience and hygiene, preventing the cap from falling on the ground.
For children, we have developed a dedicated tethered version of our Babylink cap, featuring a spiral lanyard and reduced weight. In addition, Babylink’s 3D design includes anti-choking features, making it safer.
Design excellence behind the solution
Usability without compromise
Innovation only works if it respects the user. A tethered cap must open easily, remain unobtrusive during pouring or squeezing, and reseal reliably. These aspects are central to consumer acceptance.
Material coherence and recyclability
Gualapack’s tethered caps are designed using material-compatible polymers, such as PP and PE, supporting mono-material packaging concepts where possible. This consistency helps simplify recycling pathways and supports broader circularity goals.
Integration with filling lines
From a manufacturing perspective, Gualapack’s tethered caps are developed to work seamlessly with our spouted pouch filling lines.
Their implementation requires careful consideration of:
- Cap feeding and application
- Line speed and automation
- Clearance during filling
Built on Gualapack’s Technology Crossover approach, the fully integrated system brings pouches, caps, spouts, and filling equipment together into a single, coordinated platform designed for smooth and reliable operation.
Different designs
Finally, a range of attractive, emotionally engaging designs, such as the Mood cap, has been developed, allowing brand owners to select or customize solutions that align seamlessly with their brand identity, style, and color palette.
Looking ahead: future-ready packaging
Choosing tethered caps today is not about following a rule: it is about anticipating what packaging will be expected to do tomorrow.
By offering tethered caps ahead of regulation, Gualapack demonstrates:
- A commitment to customer needs over minimum requirements
- A willingness to lead through engineering and design innovation
- A long-term view of sustainability and compliance
Key takeaways
Tethered caps in flexible packaging illustrate how innovation can move faster than regulation.
They reduce litter risk, support sustainability strategies, and preserve consumer usability.
By including tethered caps in its portfolio before they are mandatory, Gualapack enables customers to adopt future-ready packaging solutions—today.
Discover more about our portfolio of spouts and caps and contact us for more informations.
