Custom pouch sizes, dimensions, and capacity

Custom Pouches are sized two ways: by their outside dimensions and by how much they hold. At Packlane, you can choose from 11 standard sizes across Stand-Up Pouches and Flat Pouches, each with an estimated capacity, or go custom if you need something more specific. 

This guide walks you through how pouch dimensions work, why capacity is important, the differences between Stand-Up Pouches and Flat Pouches, and how to pick the right size for your product.

Which pouch style is right for your product?

Start by picking the pouch style that suits your product.

• Stand-Up Pouches feature a bottom gusset that expands to help the pouch stand upright on shelves. They are often used for powdered drinks, dry snacks, and pet treats.
• Flat Pouches have a slimmer profile and are ideal for products that don’t require a self-standing package. You usually see Flat Pouches hold spices, supplements, and sample foods.

Choosing the right pouch for your products

Choose a Stand-Up Pouch if you are: 

• Selling products on retail shelves. The bottom gusset lets the pouch stand upright, so customers can easily see your product and its branding. 

• Packaging larger quantities. Stand-Up Pouches usually hold more than Flat Pouches of a similar size. For example, a 7″ x 9″ x 3” Stand-Up Pouch holds about 4½ cups, compared with 4 cups for a 7″ x 9″ Flat Pouch. This makes them a good choice for coffee, snacks, pet treats, powders, dried foods, and other bulk items. 

• Looking for resealable packaging. Stand-Up Pouches can be ordered with a reclosable zipper, which is practical for products customers open and close several times. (Flat Pouches can have one too.) 

Choose a Flat Pouch for: 

• Small or single-use products. Flat Pouches are great for samples, spices, supplements, cosmetics, seasonings, and other products sold in small amounts. 

• Saving space. Flat Pouches do not have a bottom gusset, so they take up less space before and after filling. They are also easier to pack, stack, and ship in bulk. 

• A cost-effective packaging option. Flat Pouches use less material than Stand-Up Pouches. They are a practical choice for lightweight products that do not need to stand up on their own.

Understanding Pouch dimensions

Once you’ve picked a style, the next step is understanding how its size is listed.

Stand-Up Pouches are usually measured by width, height, and gusset (W x H x G).

• To find the width, measure straight across the front of the pouch when lying flat.

• Measure the height from the bottom edge  to the top edge, also while lying flat.

• The gusset is the expandable bottom part that lets the pouch stand up and hold more. To measure it, expand the gusset and measure from front to back at the widest point.

Flat Pouches do not have a bottom gusset, so you only need to measure the width and height (W × H).

• The width is measured across the front of the pouch.

• The height is measured from the bottom edge to the top edge.

Since Flat Pouches do not expand at the bottom, they work best for thinner or smaller products.

Why Pouch capacity matters

Besides choosing the right pouch size, you should also check the pouch’s capacity for holding its contents. Pouches, regardless of style, use outside dimensions so seals and the zipper take up some of that space. Each pouch size fits a certain amount. At Packlane, for instance, a 4.375″ x 6″ x 2″ Stand-Up Pouch holds about 1 cup.

There are a few more things to consider when thinking about capacity:

• Stand-Up Pouches and Flat Pouches often hold different amounts, even if they look like they are the same size.

• The shape and density of your product can also change how much fits in a pouch.

• If your product is portioned by weight instead of volume, be sure to calculate volume for each product individually (1 lb of marshmallows has more volume than 1 lb of coffee)

That’s why Packlane lists an estimated capacity for every standard pouch size, so you can pick the best option for your product.

Standard Stand-Up Pouch sizes

Standard Flat Pouch Sizes

Tips for choosing the right Pouch size

Choose based on the filled product. Measure your product with its packaging in mind. Loose items, powders, and solids may take up different amounts of space, even if they have the same weight.

Leave room for sealing. Avoid filling the Pouch all the way to the top. Leave some space so it can be sealed well and customers can open it easily.

Consider shelf display. Choose a Stand-Up Pouch if your product needs to stand upright on store shelves. If you plan to hang your product on display hooks, add a hang hole. It’s available on both Stand-Up Pouches (round or Euro-style) and Flat Pouches (round).

Test before ordering. If you’re not sure which size to choose, start with a small run. Pouches have a minimum order of 100, so you can test the fit and look before committing to a bigger order.

Frequently asked questions 

How do I choose the right Pouch size for my product?  

First, pick the Pouch style that works best for your product. Next, choose a size based on your product’s measurements and how much you need to pack. If you’re unsure, start with a small run (pouches have a 100-unit minimum) before ordering more.

Can I use the same Pouch size for different products?  

Yes. Many businesses use one pouch size for different products, as long as each product fits well and stays within the pouch’s recommended capacity.

Can I fill a Pouch to its maximum capacity?  

It’s better not to fill the Pouch all the way. Leave some space at the top so you can seal it properly and keep your product looking good and fresh. 

Can custom Pouches be resealed?  

Yes, you can order Stand-Up and Flat Pouches with resealable zipper closures. These are great for products that customers open and close more than once.

How do I know if I need a custom Pouch size?  

If your product doesn’t fit a standard size or needs a special shape or capacity, a custom pouch size might be a better choice for fit and appearance.

Final Thoughts

Finding the right custom Pouch is easier when you start with your product, then match it with the right style, size, and capacity. A well-fitting Pouch looks better on the shelf, keeps your product secure, and avoids wasted space. Whether a standard size works perfectly or you need custom dimensions for a unique product, Packlane offers Stand-Up and Flat Pouch printing in a variety of sizes and types to help you create packaging that fits just right.

• Author the Author

Packlane

Editorial Team

At Packlane, we believe great things come in custom packages, whether they’re small cartons, large printed shipping boxes, or anything in between.

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Packlane

Editorial Team

At Packlane, we believe great things come in custom packages, whether they’re small cartons, large printed shipping boxes, or anything in between.

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