Custom Flat-Bottom Pouches

Materials and Barrier Layers

Flat-bottom pouches are made from laminated films, with each layer doing a job. An outer layer takes the print and gives the finish. A middle barrier layer, often a metallised film or aluminium foil, blocks oxygen, moisture and light. An inner layer seals the pouch and is in contact with the food, and we use food-contact grade films for that layer.

For products that need less protection, such as dry pasta or pet treats with a short shelf life, a lighter barrier is enough and keeps costs down. For coffee and products sensitive to moisture, a high barrier is worth it. Kraft paper outer layers give a natural, artisan look, while gloss or matte films give a modern, polished finish. Clear windows can show the product, though a window reduces the light barrier, so they are best kept small for light-sensitive products like coffee. A paper-look outer over the same barrier is available as kraft stand-up pouches.

Closures, Valves and Handy Extras

Most flat-bottom pouches have a resealable closure. A press-to-close zip is the standard; a pocket zip or slider zip is easier for customers with limited grip, and a tear notch above the zip lets them open the pouch cleanly. Degassing valves are essential for freshly roasted coffee and are placed on the front or back panel.

Other extras include hang holes for retail display, rounded corners that feel softer in the hand, and a clear stripe window down a side gusset that shows the fill level. Tin ties are another resealing option, popular with artisan coffee roasters who like the hand-folded look.

Think about how the pouch will be filled. Many small producers fill by hand through the open top, then seal with a heat sealer above the zip. A wider pouch is easier to fill by hand, and a little extra headspace makes sealing quicker and neater. If you use a filling machine, send its specification so we can match the pouch dimensions to it. For single-serve portions, tear notch pouches without a zip keep costs down.

Designing for Five Panels

Treat the pouch as a three-dimensional object rather than a flat label. Shoppers often see the side gusset first, especially when pouches are stacked in a row on a shelf. A bold colour or pattern on the gussets makes the whole row look striking and helps customers spot their favourite flavour.

The base is the least seen but useful for batch codes, best-before dates and storage guidance. Keep fine text off the fold lines, because the material bends there. Our proof shows the artwork on each panel, and we will flag anything that sits too close to a seal or fold. You receive a free proof of all five panels before anything is printed.

Sizing and Fill Volumes

Pouches are sized by width, height and gusset depth. The same weight of different products needs different pouches: 250 g of coffee beans takes up more space than 250 g of sugar. The best way to choose is to fill a sample pouch with your product, or to tell us the product and target weight and let us recommend a size.

Leave enough headspace above the product for the zip and seal, so the pouch closes cleanly without crushing the contents. If you sell several weights, choose sizes with the same width and gusset so pouches line up neatly on a shelf even when their heights differ.

Shipping is another factor. If you sell online, check that your most popular pouch fits through a letterbox inside a slim mailer, which can save customers a trip to the depot. A slightly shorter, wider pouch often fits where a tall, narrow one would not. Our guide explains measuring fill volume rather than weight for loose products.

Fill a Sample Pouch to the Target Weight, Then Weigh the Air

Flat-bottom pouches are sized by volume, and coffee beans, ground coffee and granola all take different space at the same weight. Fill any similar pouch to your target weight, note how full it is, and tell us the product and the weight. Decide on the extras in one go: a one-way valve for freshly roasted coffee, a zip for products used over weeks, a tear notch for a clean opening and a window only for products that are not light sensitive. Plan artwork for all five panels, because the gussets are often what shoppers see first, and keep a plain area on the base for dates. Roasters launching guest blends sometimes pair the pouch with a coffee box for subscription deliveries.

Send the product, fill weight, features and artwork, and a custom quote comes by email within one working day. The free proof shows every panel. Production takes 4 to 7 working days after approval, pouches arrive by tracked courier to UK mainland addresses, and misprints or damage reported within 10 days are reprinted or refunded.