Pouch format decides how a pack stands, how much of it can be printed, how it is filled and what it costs to make, even when the film is identical. Two brands can put the same 500 g of granola into the same laminate: one pouch slumps forward and hides its logo, the other stands square with a printed side panel facing the aisle. This guide compares the main pouch types used for custom printed stand-up pouches and related flexible packs, so you can match format to product, filling method and display.
What are the main pouch types?
The five formats buyers meet most often are the stand-up pouch (doypack), the flat-bottom or box pouch, the side-gusset bag, the quad seal bag and the three-side-seal flat pouch. They differ in how they stand, how much printable surface they offer, how they are filled and how much they cost to make.
| Format | How it is built | Stands on shelf | Print panels | Typical fill range (indicative) | Relative unit cost |
|---|---|---|---|---|---|
| Stand-up pouch (doypack) | Front and back panels with a folded gusset sealed into the base | Yes | Front, back, base gusset | Small sachet sizes up to around 1-2 kg | Moderate |
| Flat-bottom (box pouch) | Front, back, two side gussets and a flat rectangular base | Yes, very stable | Five: front, back, two sides, base | Typically 250 g upwards; strong for 500 g-several kg | Higher |
| Side-gusset bag | Front and back with gussets folded into each side; back seal (fin or lap) | When filled and squared; often folded over | Front, back, two gussets | Mid to large fills | Moderate |
| Quad seal bag | Side-gusset bag with all four vertical corners sealed | Yes, defined corners | Four sides plus base | Mid to large fills | Moderate to higher |
| Three-side seal (flat pouch) | Two panels sealed on three sides, open at top for filling | No (lies flat or hangs) | Front, back | Samples, single portions, small fills | Lowest |
Fill ranges overlap widely and depend on bulk density: a pouch that holds 1 kg of sugar holds much less weight of puffed cereal. Use the ranges only as orientation, then size properly with our guide to pouch sizes.
Stand-up pouch (doypack)
The stand-up pouch is the default printed retail pouch because it stands on its own, offers two large print panels, accepts almost every feature, and is efficient in film use. The folded bottom gusset opens when the pouch is filled and forms an oval base.
Bottom gusset styles
Not all stand-up pouches have the same base. The bottom construction affects stability, how much weight the pouch carries and how it looks:
- Round bottom (often called Doyen or "doypack" bottom): the gusset is sealed with curved seals at each side. A classic look, suited to light and medium fills.
- K-seal: angled seals at the bottom corners shaped like a "K". They spread the load and help heavier or denser fills stand upright with less stress at the corners.
- Plough or folded bottom: the gusset is formed from the same web without curved corner seals, giving a wider, flatter base. Used for heavier fills and larger sizes.
If you compare quotations, check which bottom each supplier assumes. The difference changes both appearance and capacity.
Strengths and limits
- Strengths: good shelf presence, efficient material use, broad feature compatibility (zipper, tear notch, valve, window, spout, hang hole), works on manual and automatic pre-made pouch fillers.
- Limits: tends to bulge and lean forward when full, so the front panel curves; less volume-efficient than a box pouch for the same footprint; side profile is narrow.
Flat-bottom pouch (box pouch)
The flat-bottom pouch combines a flat rectangular base with two side gussets, so it stands like a carton. It is the premium choice for coffee, larger pet-food packs and granola, and often carries a pocket zipper or slider at the top.
Its five printable panels let you put brand on the front, product information on the back, and claims or recipes on the sides, which face the shopper when packs are displayed side-on. A flat base also gives good volume efficiency, so a box pouch often has a smaller footprint than a stand-up pouch of the same capacity. The trade-offs are higher conversion complexity, higher unit cost, and fewer suppliers able to make it on high-speed equipment. Filling usually needs a wider opening or adapted filler. In the UK it is often called a "box pouch"; in the US "flat-bottom bag" or "box bottom bag" are more common.
Side-gusset bag
The side-gusset bag is the traditional coffee bag: front and back panels with gussets folded in at each side and a long back seal. When filled and squared, it stands; many are folded over at the top and closed with a tin tie or label, or heat-sealed with a degassing valve on the front.
Side-gusset bags are material-efficient for larger volumes and run well on both pre-made and form-fill-seal equipment. Their weaknesses are a less stable shelf stance than flat-bottom pouches unless well filled, and fewer reclosure options (a top zipper is possible but less common than on stand-up pouches). The back seal can be a fin seal (inside faces sealed together, standing up as a fin) or a lap seal (inside face sealed to outside face, flatter but needing a sealable outer surface).
Quad seal bag
A quad seal bag is a side-gusset bag with all four vertical corners sealed, giving crisp edges and a box-like profile. The corner seals add rigidity, help the bag hold its shape when partly empty and allow the gussets to be printed as distinct panels. It is common for coffee and pet food where a square, upright pack is wanted without the cost of a full flat-bottom construction. Conversion is slower than a simple side-gusset bag, so cost sits between side-gusset and flat-bottom.
Three-side seal flat pouch
The three-side-seal pouch is two panels sealed on three edges, filled through the open top and then sealed. It does not stand, but it is the simplest and cheapest pouch to produce and fill, and it lies flat for mailing or hangs from a peg on a display. Typical uses are samples, single servings, spices, seasonings, cosmetics sachets and hang-sell items. Zippers, tear notches and hang holes are all possible. A two-side seal variant (folded at the bottom) exists for some applications.
Spouted and shaped pouches
Stand-up pouches can be fitted with a spout and cap for liquids and purées, such as sauces, baby food, drinks and household liquids. The spout is usually sealed into the top or a corner. Shaped pouches use a contoured die-cut for brand impact but waste more film and need custom tooling. Both formats need technical review because spout fitments, seal integrity and filling methods are application-specific.
Which pouch format should you choose?
Start from fill weight and display, then check filling equipment and budget. These decision rules cover most cases:
- Light to medium fill, full-colour retail display, need for features: stand-up pouch.
- Heavy or bulky fill, or a premium brand wanting side panels and a carton-like stance: flat-bottom pouch.
- Coffee on a tight budget or a form-fill-seal line, valve on front, fold-over closure acceptable: side-gusset bag.
- Square profile for coffee or pet food without full flat-bottom cost: quad seal bag.
- Samples, single servings, mailers or peg display: three-side seal flat pouch.
- Liquids and purées: spouted stand-up pouch.
- Already running a form-fill-seal machine: check which formats your machine can make from roll stock before choosing; that may decide the format for you.
| If your priority is... | Best fit | Second choice |
|---|---|---|
| Lowest unit cost | Three-side seal | Stand-up pouch |
| Maximum shelf stability | Flat-bottom | Quad seal |
| Maximum print area | Flat-bottom | Quad seal |
| Feature flexibility | Stand-up pouch | Flat-bottom |
| Volume efficiency for bulky fills | Flat-bottom | Side-gusset |
| Short runs with several designs | Stand-up or three-side seal (digital print) | Flat-bottom |
Does format affect cost, recyclability and shipping?
Format changes the amount of laminate per pack, the number of seals and the complexity of pouch making, all of which influence cost. It also affects transport: flat-bottom and quad seal packs fit outer cases more efficiently when filled, while empty stand-up and flat pouches ship compactly flat. Format itself does not decide recyclability; the laminate and components do, so a recyclable mono-material structure can be made in most formats, subject to converting trials. See recyclable mono-material pouches and the PPWR. For zippers, valves and other add-ons that each format can carry, see pouch features.
Cost drivers across all packaging types, including format complexity, are summarised in our packaging cost drivers guide.
Format checklist for a quotation
Before asking for prices, decide or describe:
- Preferred format and bottom style (round, K-seal, plough; flat-bottom; side-gusset with fin or lap seal; quad seal).
- Product, fill weight and bulk density, or a product sample.
- Target dimensions or a reference pouch.
- How the pouch is filled: by hand, pre-made pouch filler, or form-fill-seal from roll stock.
- Display method: shelf, peg hook, shipper box, e-commerce.
- Features required on the format.
Send this with your artwork brief via our custom printed stand-up pouches page or contact page, and the format details are confirmed at technical review.