Custom Chip Bags
Chips are fragile, oily and mostly air, which makes the bag a cushion as much as a container. Get the headspace and the film right and the product survives the trip; get it wrong and you ship crumbs.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the pillow / back-seal pouch structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures chip bags actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
The bag is inflated on purpose, so build in the headspace
Chips travel in a flushed bag that is typically half to two-thirds gas by volume. That cushion is the whole reason they arrive whole. Size the bag for the inflated pack, not for the settled product, or you will end up with a bag that looks half empty on the shelf because the artwork was drawn for a flat one.
The mistake that costs a print run
Heavy ink coverage over the seal area
Oil migrates into the film over shelf life and solid ink laydown across the seal band makes an already marginal seal worse. Keep the top and bottom seal zones clear of dense coverage, keep them clear of metallic inks entirely, and design the back seam so the artwork can tolerate a quarter inch of overlap either way.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom chip bags
Why does my chip bag look half empty?
Because it is, by design — the gas cushion is what stops the chips breaking. The fix is not less headspace; it is drawing the artwork for the inflated shape so the panel still reads correctly when the bag is puffed.
Pillow bag or stand-up pouch for chips?
Pillow for single-serve and clip-strip sizes, stand-up for anything that needs to face forward on a shelf or be reclosed. A stand-up gives up some of the cushion, so it suits sturdier cuts better than thin fried slices.
Does the film need a barrier for chips?
Yes. Oxygen turns the frying oil rancid long before the chips go soft, so a metallised or high-barrier structure is doing the real work; a plain printed film will not hold the flavour to the date on the pack.