The Fold · From the factory floor
What are the different types of pouches?
The main types of pouches are the flat (3-side seal), stand-up, no-gusset, flat-bottom, side-gusset, quad-seal, pillow, stick pack and spout pouch, plus custom shaped pouches, and the choice comes down to whether the pouch has to stand up, how much it holds and whether it reseals or pours.
The pouch types, side by side
| Type | What it is | Best for |
|---|---|---|
| Flat (3-side seal) | A simple flat pouch sealed on three sides. | Samples, singles and the lowest cost. |
| Stand-up | Stands upright on a shelf thanks to a bottom gusset. | Retail snacks, coffee and supplements, resealable. |
| No-gusset | The stand-up's shape without the bottom gusset: a flat lay-flat zipper bag. | Flat resealable packs that don't need to stand on a shelf. |
| Flat-bottom (box-bottom) | A boxy pouch with flat front and back panels for premium shelf presence. | Coffee, premium dry goods and big fills. |
| Side gusset | Expands at both sides into a tall, roomy bag. The classic coffee bag. | Coffee beans and bulk dry goods. |
| Quad seal | Sealed at four corners for a crisp, freestanding box shape. | Premium bulk fills, pet food and coffee. |
| Pillow (back-seal) | A simple tube sealed top and bottom, with a seam down the back. | Snacks, single-serve and high-speed fills. |
| Stick pack | A narrow pillow bag: a slim tube sealed flat at both ends. | One dose of powder, such as electrolytes, greens, pre-workout, coffee and sugar. |
| Spout (corner or top) | A pouch with a screw-cap spout, on the angled top corner or centred in a straight top seal. | Liquids, gels, baby food and drinks. |
| Shaped (die-cut) | A pouch cut to a custom outline shape. | Standout retail shapes and branding. |
What a gusset is
A gusset is a fold of extra film that lets a pouch expand. It is the single biggest difference between pouch types. A stand-up pouch has a gusset across the bottom, which opens out into a base so the bag can stand. A side-gusset bag has gussets down both sides, which is why it grows into a tall, boxy shape when it is filled. A flat pouch has none, which is why it lies flat and costs the least.
TWOFORM designs stand-up gussets from 20 to 250 mm (0.8 to 9.8 in).
How to choose
- It must stand on a shelf and reseal: stand-up.
- Premium look and a big fill, such as coffee or pet food: flat-bottom or quad seal.
- A traditional coffee bag: side gusset.
- One dose of powder: stick pack.
- A liquid or a gel: spout.
- A sample or a single serve at the lowest cost: flat or pillow.
- A shape that makes people stop: shaped.
How big or small can each type be?
Sizes differ by type. Gusseted pouches such as the stand-up start at about 60 × 89 mm (2.4 × 3.5 in), flat pouches start at 50 × 60 mm (2.0 × 2.4 in), and stick packs go as narrow as 15 mm (0.6 in). The full limits are in the guide on the smallest size for a stand-up pouch.
Frequently asked questions
What is the difference between a stand-up pouch and a flat-bottom pouch?
A stand-up pouch stands on a bottom gusset. A flat-bottom pouch has flat front and back panels and a boxy shape, which gives it a more premium look on the shelf.
What is a stick pack?
A narrow pillow pouch, a slim tube sealed flat at both ends with a seam down the back. It is made for one dose of a powder.
What is a quad seal pouch?
A pouch sealed at four corners, which gives it a crisp, freestanding box shape. It is used for premium bulk fills like pet food and coffee.
Which pouch is used for coffee?
The side gusset bag is the classic coffee bag. Flat-bottom and quad seal pouches are the premium options.
What is a gusset?
A fold of extra film that lets a pouch expand. A bottom gusset lets a stand-up pouch stand, and side gussets let a bag open into a tall, roomy shape.
Ready to try it? Design your own pouch in TWOFORM. Related reading: the smallest size for a stand-up pouch and what a dieline is.