5 Must-Have Features in a flat pouch packaging

Author: Elva

Apr. 07, 2025

Packaging & Printing

How to Design the Best Flexible Pouch for Your Needs

As producers around the world increasingly package a wider variety of goods in pouches, there is a commensurate need for full-system pouch-makers that are efficient, on time and on budget, and have the knowledge and versatility to cross many industries.

HaiPak are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

If your organization is seeking a company to produce your pouches, or if you have already engaged a supplier, make sure they partner with you to develop a finished product that not only protects your product effectively and economically but also captures consumer attention. A well-designed pouch should consider these elements:

1. Volume and Weight of the Product — The dimensions and bulk of your product along with its weight will drive not only the material for your pouch but also the geometry of its design. An obvious example is that the package for 10 pounds of dog food will be different from the package for 10 pounds of resin.

2. Chemistry — An effective pouch-maker must devise solutions that are precisely suited to the characteristics unique to each product, whether it is a liquid food, an industrial or agricultural product, or coffee. For example, some products will act as solvents on the pouch materials. Your supplier’s team should include people who can test for chemical reactions in your product well before it is contained in your completed pouches.

3. Features — Flat and stand-up pouches may come with a host of features that are ideal for consumer use, such as zippers, handles, easy open seals, microwave-venting, degassing valves, spouts and other fitments, tear notches, laser scoring, 4-corner seal (patent), Your pouch supplier’s team should be advising you of these possibilities.

4. Transportation and Storage — It is possible that your pouch will be stored on a shelf over time. If so, then you must consider the construction that will allow it to stand. Under that circumstance, it is probably also important to consider the pouch’s “billboard effect” — the total graphic space on your packaging that creates visual impact and engages consumers with the product’s brand. On the other hand, if the pouches will be stacked on a pallet, then you’ll need materials with a high coefficient of friction (COF), or cohesiveness, to keep them from sliding.
As the pouches are transported, which barriers will be required? Must you protect against light? Moisture? In those cases, your advisors should be offering you a wide range of barrier materials, from EVOH, aluminum oxide- or silicon oxide-coated polyester and metalized polyester to PVdC-coated Polyester and aluminum foil.

5. End Use by Consumer — Sample questions: Will consumers use the pouch more than once? If so, what type of reclosure will it need? If on the other hand the pouch is for single use, then how should it be opened? Will you need to provide a spout or other pouring device?
There are different considerations if the pouch will be used to cook food. Will the bag be boiled or microwaved, or will hot water be poured into the bag? Some foods like yogurts and kids’ snacks do not require cooking at all. But whatever the method of preparation or the final state of the food, a god pouch designer should at least be able to suggest the material you need to achieve your final goals.

As U.S. consumers increasingly accept flexible pouches over rigid containers, packagers will have more opportunities to achieve results similar to those listed above. Your pouch supplier should have the people, the professional experience, and the assets to meet your critical priorities and help you bring your product to market successfully.

Fres-co System USA, Inc. serves our customers with pouches that are designed to fulfill a wide range of packaging requirements. We have more than 30 years of success in the flexible packaging business, and it shows. Learn how we can design a solution for your unique needs such as stand-up pouches, 4-side seal pouches, and more.

For more information on the impact of packaging, download our guide below.

A Complete Guide for Flat Pouch Packaging

A Complete Guide for Flat Pouch Packaging

Flat pouch packaging offers a flexible, reliable, and convenient packaging solution. But choosing the best sachet pack can be a daunting task. That’s why today’s guide will answer all the questions you’ve been asking about flat pouch packaging.

1. What is flat pouch packaging?

Flat pouch packaging, as the name suggests, has 2 or more sealed sides with additional features to make them more convenient to use. Flat pouch packaging is also suitable for sample packs or limited/single serving sizes. Essentially, it can be used to package smaller quantities of products.

2. What types of flat pouch packaging are available?

There are many flat pouch packaging options. A variety of flat pouch packaging varies based on factors such as additional features, lamination process, product preference, and selected materials. Some of the flat pouch packaging types available in the market are:

1) Available in a flat pouch made of aluminum foil with additional features

Aluminum foil flat bottom plastic flat pouch packaging

Ziplock Food Aluminum Flat PouchPackaging

Daily Product Aluminum Flat PouchPackaging with Tin Tape

Dog food is packed in an aluminum laminated flat-bottom plastic flat pouch

2) Flat pouch packaging combined with additional features

Coffee tin belt flat pouch packaging

Printed flat pouch packaging

Flat pouch packaging for food

Ziplock food flat pouch packaging

Matte gold plastic flat pouch packaging

Zipper three-side seal flat pouch for food packaging

3) Flat pouch packaging made by an additional lamination process

Cat food laminated flat pouch packaging

Food packaging in laminated flat pouches

Laminated plastic flat pouch packaging

Laminated flat pouch packaging

Dog food laminated flat-bottom plastic pouch

Flat pouch packaging

Laminated flat bottom plastic flat pouch packaging

4) Flat pouch packaging made from recyclable natural materials combined with additional features

Packaged in recyclable white Craft flat pouch with resealable zip lock

Recyclable white craft paper flat pouch packaging with ziplock

Packaging with a window made from recyclable white craft paper laminated flat pouches

Packaged in recyclable white craft laminated flat pouch with ziplock

Recyclable white craft paper laminated flat pouch printed packaging

Recycled brown kraft paper laminated flat pouch packaging

Recycled brown craft laminated flat pouch with ziplock

Recycled brown craft laminated flat pouch packaging with hand holes

Recyclable brown craft paper flat pouch printing packaging bag

Recycled brown kraft paper flat pouch packaging with customized window

Recyclable brown craft paper windowed flat pouch packaging

Recyclable brown craft paper flat pouch printed packaging

Recycled brown kraft paper flat pouch packaging with hand holes

Recycled brown kraft paper flat pouch packaging

5) Packed in a flat pouch made of plastic material with additional features

Tea self-sealing plastic flat pouch packaging

Food packaging in self-sealing plastic flat pouches

Coffee Plastic Flat Pouch Packaging With Valve

Printed plastic flat pouch packaging

Plastic flat pouch packaging with seeds printed

Coffee is packed in a ziplock plastic flat pouch

3. What are the characteristics of flat pouch packaging?

Brand owners often have specific requirements for manufacturing companies as to what characteristics their flat pouch packaging should have. These features increase the user-friendliness of the flat pouch packaging and make it compatible with its products. When people buy products, they look for those that come in great packaging. Some features of flat pouch packaging include:

Due to its user-friendliness, flat pouch packaging is an easy packaging option for a wide variety of products.

This is an economical package.

Their design style allows them to effortlessly customize label placement and valve position.

Flat pouch packaging is versatile as it can pack a wide range of products.

This packaging is reusable.

It is environmentally friendly.

It is FDA-approved.

It is 100% food safe.

Flat pouch packaging has excellent barrier properties to protect products from UV rays, chemicals, moisture, and other elements.

Flat pouch packaging is heat-sealable to create a tamper-resistant and air-tight environment.

It is convenient because it comes in different formats and sizes.

It is lightweight and ships flat for easy storage.

Some of them have a matte finish which looks more professional and luxurious.

Flat pouch packaging has a laminated interior to increase the shelf life of the product.

4. Is flat pouch packaging safe for human food?

Absolutely. Flat pouch packs are 100% food safe as they are BPA-free. The sachet packaging is also made of high-quality hygienic materials. The flat pouch packaging is printed with high-quality ink, which is safe and reliable.

5. What is the best design for flat pouch packaging?

You can get flat pouch packaging that suits your requirements and the products to be packed. For flat pouch packaging, the following design styles are recommended:

1) Three-sided sealing design

The best design style for flat pouch packaging is the three-sided seal design. It has a single-sided clear panel for displaying your products. Flat pouch packaging is sealed on three sides. This design style makes flat pouch packaging suitable for vacuum sealing.

2) Central seal design

Center seal design styles are available for flat pouch packaging. This design provides a strong seal for flat pouch packaging on the center back. This design protects the product from:

moisture

air

other external factors

6. Do flat pouch packaging companies offer labeling services?

Yes, they have. Flat pouch packaging companies provide labeling services to their customers. The company has semi-automatic machines for self-adhesive label application. The machines are equipped with a variety of pouch packaging and label sizes, allowing companies to easily meet their customers’ labeling needs. Using company technology, labels are applied with low waste rates and high precision. As a result, there is limited flat pouch packaging waste due to inaccurate label placement.

7. What are the additional features of flat pouch packaging?

Flat pouch packaging needs additional features to improve its ability to store products and make them easy to use. The type of additional features included in the flat pouch packaging depends on the customer’s requirements. Some additional features are:

1) Hanging hole

This feature makes flat pouch packaging ideal for point-of-sale merchandise. It is used to hang flat pouch packs while on display so that customers can easily notice them

2) Exhaust valve

This feature applies to their coffee products. Coffee products tend to release gas, which can cause the flat pouch package to burst if left in the package. The vent valve helps release these gases and prevents oxygen from entering the package. It helps to ventilate the flat pouch packaging when placed in the microwave. The steam generated when reheating the package passes through the ventilation holes.

3) Tear opening

The tear opening allows for easy and clean tearing of the flat pouch packaging for single-use flat pouch packaging.

4) Laser perforation

This feature facilitates easy tear/open-controlled tear propagation while maintaining barrier properties and package strength. It is a straight silhouette and can be zipped as well as resealed. It helps with moisture release for fresh produce, burst protection during transport, and controlled airflow.

5) Windows

This feature allows a sneak peek at the package to see what’s in it. It is usually a transparent material with a plastic film to protect the product from UV rays.

6) Fillet

This feature helps prevent injuries caused by using packages with sharp corners.

7) Die-cut shape

Die-cut shapes provide structural advantages, such as preventing stress cracking or providing additional stability. It further adds convenience by making flat pouch packaging easier to use. It also strengthens the company’s brand.

8. Can you customize the flat pouch packaging?

Flat pouch packaging comes in a variety of customizable options. You can customize printing, materials, resealable features, additional features, stamp styles, and sizes. Flat bottom pouches are a type of flexible packaging that provides stability due to their flat rectangular base and gusseted sides, allowing for more volume. It’s gonna be a little different.

1) Material

The material selected is based on the customer’s packaging needs. Flat pouch packaging is made of food-grade solvent-free packaging material. Customers can choose from craft paper, foil lamination, metalized film, or clear film.

2) Size

The size of the flat pouch packaging depends on the amount of product the customer wishes to store. Packs can be small, medium, large, or custom sized.

3) Additional functions

Flat pouch packaging has integrated additional functions to increase its functionality and user-friendliness. These features may include hanging holes, rips, valves, etc.

4) Printing

The customer chooses the best printing process and ink. Printing options depend on the customer’s requirements and designs. Generally, the choice is based on cost, quality, ink, and color quantity.

5) Resealable feature

Flat pouch packaging can have a slider or press-to-close zippers. The slider is easy to open and convenient, while the zipper is economical.

6) Center seal style

Flat pouch packaging can be designed with either a center seal or a three-sided seal. Depending on the product, customers can choose from a variety of options. A flat pouch packaging can be customized in these ways.

9. How much does the flat pouch packaging cost?

The cost of flat pouch packaging is affordable. The cost of flat pouch packaging is relatively low because it uses less material to make. The raw materials used to make the pouches are also inexpensive and readily available. Packaging is produced in bulk so there are economies of scale. In addition, the overall production cost of flat pouch packaging is lower due to the low labor costs and the equipment used.

10. What products are flat pouch packaging suitable for?

Flat pouch packaging is suitable for products with fast turnover. Some of the products packaged in flat pouches are:

coffee products

nut

seed

tea

whole grains

snack foods

powder mix

bacon

jerky

chips

dried beef

For more lidding filminformation, please contact us. We will provide professional answers.

bath salts

seafood and fish

frozen food

spices

sauces and soups

pet Treats and Food

11. What factors need to be considered before purchasing flat pouch packaging?

When you decide to buy flat pouch packaging for your product, you have to make sure it’s the right one. Some factors to consider before purchasing flat pouch packaging are:

1) Cost

The type of flat pouch packaging you choose should reflect the amount you are willing to pay. Due to its added features, custom flat pouch packaging costs more than standard flat pouch packaging. Additional features may include more materials or features, which translates into higher costs.

2) Material

Flat pouch packaging can be made from a variety of materials. These range from natural and compostable materials such as craft paper to recycled materials such as plastic polymers and metal foils. Different materials also have various properties that improve the functionality of flat pouch packaging and make them suitable for packaging products.

3) Design

Flat pouch packaging must be designed to fit the product being packaged. It must also provide enough space for branding purposes. Designs can be 3 side seal or center seal design styles.

4) Purpose

One should determine whether a flat pouch packaging solution is suitable for packaging their target product. Flat pouch packaging is versatile and can be used to package a wide range of products.

5) Dimensions

Flat pouch packaging comes in different sizes; bags can be small, medium, large, or custom sized. The number of products a customer intends to pack in their flat pouch pack determines the size of the pack. If customers intend to pack a small amount of product, they will buy the small-size flat pouch packaging and vice versa.

12. What sealing options are available for flat pouch packaging?

You can use different sealing options to seal the face and sides of your flat pouch packaging. Some available sealing options are:

1) Heat sealing

A heat seal is required to seal the flat pouch packaging. It involves the use of a heat sealer that generates the heat needed to seal the package. Use sufficient pressure to press the heat sealer against the surface of the material film.

2) Vacuum-tight

While vacuum sealing is not often used as a sealing option for flat pouch packaging, it can be used. Vacuum sealing requires nitrogen gas to be introduced into the bag to remove any oxygen. Vacuum sealing is done using a chamber vacuum sealer.

13. Are flat pouches suitable for pet food?

Yes, they are. Pet food packaged in flat pouches has excellent barrier properties against pests… They pack fish food, bird food, and food for dogs and cats separately. In addition, they meet FDA requirements for food-grade packaging.

14. What materials are used to make the flat pouch packaging?

The materials used to make flat pouch packaging must meet the requirements of European and American food contact regulations. They also comply with EN and ASTM D. These materials offer excellent oxygen and moisture barrier properties, freeze safety, heat/vacuum sealing, exceptional strength, and more. They depend on the product to be packaged as well as the customer’s preference. Flat pouch packaging is made from materials such as:

1) Craft paper

It is a 100% compostable material. It can be recycled, so it is environmentally friendly. It complies with FDA requirements for direct food contact Craft paper provides a good barrier to protect the product from oxygen, UV rays, moisture, chemicals, etc. Since craft paper is odorless, it will not impair the taste of edible products when used to package products.

2) Linear low-density Polyethylene (LLDPE)

This material is highly recyclable. It is responsible for the lightweight properties of the flat pouch packaging. It is stiff and has a high tensile strength, giving the bag stability.

3) Aluminum foil

This material provides a complete barrier against oxygen, moisture, pests, and punctures. It protects products from extreme temperatures and is therefore used to package microwavable products. It helps to prolong the shelf life of the product i.e. in terms of taste and smell of the product

4) Vacuum metalized polyester film (VMPET)

VMPET has high barrier properties and costs less than aluminum foil. It has a bright metallic effect. It also has an excellent aroma, light, and moisture barrier.

5) Polyethylene terephthalate (PET)

PET has moderate oxygen and high moisture resistance. PET is used to make the surface and laminate layers of flat pouch packaging.

6) Nylon

Nylon material is suitable for flat pouch packaging because of its high-temperature end-use. Has good vacuum retention and sealing. Nylon is suitable for barrier and printing layers in flat pouch packaging.

15. Is the flat pouch packaging leak-proof?

Of course. Flat pouch packages are sealed on different sides with heat and pressure. Reinforcement helps prevent packaging from breaking or leaking. To ensure the packaging is leak-proof, a leak test is performed during the manufacturing process. Leak testing focuses on whether the selected material will prevent leakage. Likewise, you can use a water bath test to determine the likelihood of a flat pouch package leaking. The test involves placing the sachet package under water and applying pressure to it until it leaks.

16. What colors are available in the flat pouch packaging?

Flat pouch packaging comes in different colors so customers can choose from a wide range of colors to suit their products. Some available color options for flat pouch packaging are:

Matt White

matte black

Matkin

black gloss

17. Is the flat pouch packaging reusable?

Yes, flat pouch packaging is reusable. After first use, wash the sachet packaging in hot water and allow it to dry. After drying, the sachets are used to package other products and closed with a zipper. Dry flat pouch packaging ensures that the product is protected from moisture or water. However, if the flat pouch package is torn using the tear opening, it cannot be used to package other products.

18. What is the difference between stand-up pouch and flat pouch packaging?

Although stand-up pouches and flat pouches are both flexible packaging solutions, there are differences between them. The two packages differ in the following ways:

1) Benefits

Flat pouch packaging offers an excellent solution for cost-effective packaging. Compared with stand-up pouches, flat pouch packaging is relatively simple to design and manufacture. Although the design and manufacture of stand-up pouches are not complicated, they are more involved than flat pouch packaging. Flat pouch packaging is available in different sizes and materials and can be customized to fit any type of application or product. This package is usually hermetically sealed, providing a protected environment for the packaged product and showing evidence of tampering.

2) Retail environment positioning

Due to its simplicity, it is suitable for fast-moving goods. Stand-up pouches are simple and easy to make, while flat pouches are the simplest packaging solution. Because of this capability, it is suitable for quick turnaround products and can be hung on a display using the hanging hole add-on. Stand-up pouches can be used for retail products, but are not as effective for fast-turnover products. The differences between the two packaging solutions are limited because they are flexible packaging types. They also have additional features that improve their functionality and user-friendliness.

19. Is the flat pouch packaging FDA-approved?

FDA-approved grade materials make packaging solutions safe and secure. They also make the graphics extra vibrant With the FDA Approved Mark, consumers can be assured of the safety and quality of their flat pouch packaged products.

20. What are the dimensions of the flat pouch packaging?

Dimensions come in a variety of sizes and can be used to pack large and small portions for storage. Flat pouch packages are available in small, medium, large, or custom sizes. Flat pouch packaging can be 6-5/8 wide x 10-5/8 high.

21. Is flat pouch packaging environmentally friendly?

Yes, they are. Inks used for printing on flat pouch packaging are environmentally friendly and safe. Since the flat pouch packaging is reusable, there is limited waste release into the environment. Flat pouch packages are made in small sizes so they require fewer tracks to transport and store. Using fewer trucks results in burning fewer fossil fuels and limiting greenhouse gas emissions into the environment. Using compostable and recyclable materials to create flat pouch packaging reduces your overall carbon footprint.

22. What is the MOQ for flat pouch packaging?

The minimum order quantity for flat pouch packaging is 10,000 pieces.

23. How do flat pouch packaging manufacturers control the quality?

Flat pouch packaging manufacturers conduct quality checks and controls on their packaging solutions to ensure their safety and high quality. Each flat pouch package must comply with international packaging safety standards. The manufacturer conducts inspections on the design, material, and overall quality of the flat pouch packaging. Some of the tests that manufacturers perform to control quality include:

water bath test

drop test

Burst test

compression test

Puncture test

Product compatibility testing

Tensile strength test

Seal strength test

Barrier test

24. Conclusion

As you can see, there are many aspects to consider before importing flat pouch packaging from China. However, with this information, you can easily choose the flat pouch that suits all your packaging requirements. For more information on bags, please contact our sales team today.

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A Complete Guide To Flat Bottom Coffee Pouches

Versatile, sturdy, and cost-effective, flat bottom pouches have become a favourite among specialty coffee roasters. 

They offer a large surface area to communicate brand identity, and can be manufactured from a variety of materials, from kraft paper to polylactic acid (PLA). Custom printing gives roasters opportunity to provide an eye-catching advertisement for roasters, helping them stand out on the shelf, as well as preserving the quality of the product inside. 

Read on to find out about the unique qualities of flat bottom pouches, and why they’ve become such a popular packaging option for coffee roasters. 

 See also: How Can You Make Your Coffee Stand Out On The Shelf?

What Are Flat Bottom Pouches?

Put simply, a flat-bottom pouch is a five-sided, free-standing pouch with a flat, rectangular base. It has material for greater space and strength, known as gussets, on both the left and right side of the pouch, with a fastener on top. 

Most flat bottom pouches are made with kraft paper, aluminium, or LDPE. Some will combine two or more layers for added protection or aesthetic purposes. 

For example, coffee roasters that want to communicate a rustic look may choose kraft paper on the outside with an aluminium foil interior, which is an effective barrier against light, moisture, and oxygen.

Specialty coffee roasters can also choose to include additional features to maximise freshness and aroma, such as resealable zippers or degassing valves.

Thanks to their versatility and large printable surfaces, flat bottom pouches are popular among those with a strong brand identity. They can be customised with different finishes, colours, and designs, which can help roasters connect with customers. 

On the shelf, they act as excellent adverts for roasters, with a sturdy structure, flat front-facing side, and sufficient space for labels full of information. They’re ideal for those who want their product to stand out among a large variety of similar items.

How Do Flat Bottom Pouches Attract Customers?

According to a paper on the role of packaging in brand communication, packaging was initially intended to protect products, but has now evolved to become a marketing tool that “increases brand image, and stimulates consumer’s perceptions about the product”.  

Flat bottom pouches are highly effective at marketing the coffee they contain thanks to the five sides on which roasters can include information, from the provenance of the beans to instructions on brewing. 

When consumers glance at a bag of coffee on a shelf, your packaging only has a few seconds to make an impression. Therefore, the more advertising space you have, the more likely a consumer is to spot your product.

However, as well as helping your coffee stand out, extra space also allows you to present your brand’s “story” to the customer once they have the package in their hands.

Mike Peck is Starbucks’ Creative Director of Packaging. In an interview with Sufio, he says that each coffee is a work of art and that the packaging must reflect the artistry that goes into its contents. 

“There’s a lot of pride in our coffee. We talk about the first ten feet – where the coffee is grown – and the last ten feet when the customer receives their cup of coffee. Each coffee package design needs to reflect the artistry and pride in the bean.”

To do this, specialty roasters can include their coffee’s origin, roast profile, flavour notes, and roast date. They can also share details of their relationship with the coffee’s producers, recommended brewing methods, sustainability certifications, and recycling instructions. 

By communicating how your coffee directly benefits others in the supply chain, you’re further building your brand, and demonstrating its commitment to sustainability and transparency. 

Versatile Display Options

Delivering a bag of coffee that stands out on the shelf in a shop or café is only half the challenge for roasters; it must also attract attention once the consumer has brought it home. 

Joe Palozzi from New York City-based City of Saints Roasters says that when they designed their coffee packaging they wanted a distinctive, solid, reusable bag that looked great sitting on the kitchen counter. 

Not only does this act as an advertisement to friends and family, it ensures roasters maintain mind share, which means customers regularly think about and continue to be aware of their brand.

However, choosing a flat bottom coffee pouch also has a number of practical benefits. These pouches have wide, square bases that offer rigidity and stability when stacked upright. This is compared to the taller, narrower designs that are less sturdy and easier to knock over, which can be frustrating for consumers.

The stable design is more user-friendly and convenient, enabling consumers to access the coffee without spilling or wasting it. 

Eco-Friendly And Cost-Effective

According to Voyager Coffee Roasters, a common issue in the coffee industry is the perception that sustainability begins and ends with takeaway coffee cups.

However, growing concerns over the environmental impact of packaging for ground and whole bean coffee has led many roasters to switch to more sustainable options.

Flat bottom pouches have become a popular choice among these roasters as they are manufactured with less material when compared to other designs. They’re also lightweight and take up little room when empty, which translates into lower carbon emissions when transported. 

However, when full, flat bottom pouches can hold significantly more coffee than other designs, such as stand-up pouches, making them a cost-effective option as well as a sustainable one.

At MTPak Coffee, specialty coffee roasters can choose from a selection of sustainable materials for their flat bottom pouches, including kraft paper, rice paper, LDPE, and PLA. Thanks to its innovative design, a flat bottom pouch can hold a large amount of coffee, which makes them perfect for substantial orders.

We also offer fully customisable packaging that allows you to take advantage of all five sides of the bag. You can choose from a range of materials, plus a selection of features, including degassing valves, transparent windows, and resealable zippers.

For more information on flat bottom coffee pouches, contact our team here.

How to Choose the Right Pouch Size for Your Product

Pouches are the go-to packaging method for food and beverage items. Unlike boxes, pouches can extend an item’s shelf life and be resealed after opening. They’re also cheaper to ship and are more likely to stand out along the grocery aisle. It’s a win-win situation for your business and your customers. But to maximize the benefits of this packaging type, you need to get the correct pouch size for your product. Getting accurate dimensions ensures the product is protected in transit, appears presentable on display, and does not damage the items once the pouch is opened or reopened.

Stand-up vs. Flat Pouches

Before we discuss measuring pouch size accurately, it’s important to understand the difference between the two most common pouch types: stand-up and flat pouches. Understanding the structure of each is integral to getting the correct size. Stand-up pouches have a gusset at the bottom that keeps the pouch upright once filled with your item and displayed. As its name implies, flat pouches are laid flat and do not have a bottom gusset.

How to Accurately Measure a Stand-up Pouch’s Size

Volume is another important consideration in measuring your pouch’s size, especially with the stand-up type. A smaller, finer product like ground coffee will take less volume than coffee beans. When measuring stand-up pouches, you need to account for the item’s volume.

Here’s a list of the recommended pouch sizes based on their volume in cups and the weight of coffee beans and flour:


Pouch Size Volume (cups) Weight of Coffee Beans (oz.) Weight of Flour (oz.) 3.25” x 4.75” x 2” 1/3 cup 1 oz. 2 oz. 4.375” x 6” x 2” 1 cup 3 oz. 7 oz. 5” x 6.5” x 2.5” 1 & 1/3 cups 4 oz. 10 oz. 5” x 7” x 3” 1 & 1/2 cups 5 oz. 11 oz. 5.75” x 7.5” x 2.5” 2 & 1/4 cups 7 oz. 1 lb. 1 oz. 6.5” x 8” x 2.5” 3 & 1/4 cups 9 oz. 1 lb. 7 oz. 6.75” x 8.5” x 3.5” 3 & 3/4 cups 11 oz. 1 lb. 10 oz. 7” x 9” x 3” 4 & 1/2 cups 13 oz. 2 lbs. 1 oz. 7.25” x 6” x 2” 1 & 1/2 cups 5 oz. 13 oz. 8.125” x 10” x 3.5” 8 & 1/2 cups 1 lb. 8 oz. 3 lbs. 4 oz. 9.875” x 10.5” x 3” 11 & 1/2 cups 2 lbs. 1 oz. 4 lbs. 8 oz. 12” x 12.5” x 3.5” 20 & 1/2 cups 3 lbs. 9 oz. 7 lbs. 13 oz.

The pouch’s fillable area starts from below the zipper down to the bottom. To account for the volume, start from the point below the zipper closure, not from the pouch’s top edge.

Now that you have a complete picture of the pouch’s dimensions, here’s how to accurately measure its three dimensions:

Measure a stand-up pouch’s size with the following dimensions:

Width is measured from the horizontal ends of the bottom gusset or the back of your pouch.

Height is measured from the top end of the pouch until the bottom part of the gusset.

The gusset is the space that your item fills inside the pouch. Look at the bottom end of the pouch and measure the gusset from the longer ends.

How to Measure the Size of a Flat Pouch

Flat pouch dimensions are measured upon laying the package flat.

• Width is measured across the pouch’s opening.

• Height is measured from the top end until the bottom of the pouch.

Use the guide below to account for your item’s volume in a flat pouch:


Pouch Size Volume Coffee Beans (Weight) Flour (Weight) 3.25” x 4.5” 1/4 cup 1 oz. 1.5 oz. 3.375” x 5.5” 1/3 cup 1.5 oz. 2.5 oz. 4” x 6” 1/2 cup 2 oz. 3.5 oz. 5” x 5.5” 1 cup 3 oz. 5 oz. 5” x 7” 1-1/4 cups 4 oz. 8 oz. 6” x 7” 1-3/4 cups 5 oz. 12 oz. 7” x 9” 4 cups 11 oz. 1 lb. 8 oz. 7” x 12” 6-1/3 cups 1 lb. 2 oz. 2 lbs. 7 oz.

Note that these listed capacities are only approximations. We recommend measuring your pouch’s actual width and height based on the item type for precise measurements.

The FDA Regulatory Requirements for Pouches

An accurate size isn’t the only essential point to consider in selecting your packaging. The Food and Drug Administration (FDA) guidelines have specific rules for flexible food packaging, such as pouches. According to packaging law, all food packaging, including the flexible kind, is prohibited from distributing adulterating food. Food adulteration occurs when the packaging renders the packaged item unfit or unsafe for consumption.

Food additive inclusions are also considered adulterations. The FDA defines a food additive as any substance that results or is expected to affect the food’s characteristics. This can include any substance used in packing, packaging, or holding food.

There are two exemptions to the food additive regulation in flexible food packaging:

• The substance has been cleared as a direct food additive, and the dietary exposure of the compound from food contact use is less than 1% of the acceptable daily intake.

• The intended use of the substance results in dietary exposures of less than 0.5 ppb.

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