The quickest way to find out that a takeaway bag range is wrong is to watch a packing station on a busy evening. Staff reach for the large bag because two burger boxes will not sit flat in the medium; the drinks carrier goes in at an angle; tall orders are closed with a single desperate fold. The right takeaway bag sizes come from the boxes, cups and order combinations you actually sell, not from a supplier's size grid. This guide sets out a menu-based method, with worked examples, for specifying custom printed takeaway bags that fit.
Which dimensions matter when sizing a takeaway bag?
Three dimensions define a takeaway bag: width (the face), gusset (the depth front to back) and height. Width and gusset together set the base footprint, which decides whether boxes sit flat. Height decides whether the order fits and whether the top can still be folded, sealed or carried by its handles.
Dimensions are normally quoted as width x gusset x height, in millimetres in Europe and in inches in the US. Two details catch buyers out:
- Inside versus outside: the usable base is slightly smaller than the nominal width x gusset because of paper thickness, glue overlaps and fold geometry. Check whether a supplier quotes outside dimensions and allow for the difference.
- Height to the top edge: height is measured from the bottom fold to the top edge. Part of it is needed for closing, so the usable fill height is always lower than the stated height.
The base footprint is the dimension most often got wrong. A bag can have plenty of volume and still fail because its gusset is a few centimetres short of your box depth, forcing the box to tilt.
Worked examples
The examples below use hypothetical box dimensions to show the method. Your own boxes will differ, so measure them; the burger box size guide and paper food container sizes explain how those items are dimensioned.
Example 1: single burger meal at the counter
- Base layout: burger box and fries carton side by side. Width needed is about 120 + 60 = 180 mm with the fries carton turned sideways; depth about 120 mm.
- With clearance: base of roughly 195 x 135 mm.
- Height: the fries carton is the tallest item, say 140 mm, plus around 50-60 mm for folding and sealing gives roughly 200 mm of height; more if handles are used.
- Result: a mid-size SOS bag of roughly 195-200 x 135 x 200-260 mm, depending on closure and handles.
Example 2: two-meal delivery order
- Base layout: two burger boxes side by side, about 240 x 120 mm.
- With clearance: base of roughly 255 x 135 mm. Fries cartons stand in front or sit on top of the boxes.
- Height: boxes plus fries cartons stacked, or fries standing, plus closure and handle clearance.
- Result: a wider-gusset delivery bag with flat handles. A standard SOS bag of similar height usually has a gusset proportioned for counter orders and would force the boxes to stand on edge or stack, which risks lids opening.
Example 3: orders with a drinks carrier
- Base layout: the carrier must sit flat, so the base must be close to square and at least 230 x 230 mm plus clearance.
- Result: few SOS sizes come close to this footprint, because SOS gussets are much narrower than the width. Operators typically either use a dedicated square-base drinks bag, hand the carrier over separately, or use two-cup carriers that fit a standard delivery bag alongside food.
Drinks are the most common reason a takeaway bag range needs one extra size. Match the decision to your cup and carrier range; the paper cup size guide covers cup dimensions.
Common order types and the bag shape they need
| Order type | Base layout driver | Bag format usually suited |
|---|---|---|
| Sides, desserts, single snack | Small carton or wrapped item | Small SOS without handles |
| Single meal (box plus side) | One box plus carton side by side | Mid-size SOS, with or without handles |
| Two to three meals | Boxes side by side, sides on top | Wide-gusset delivery bag with flat handles |
| Family or group orders | Several boxes in two layers | Large delivery bag; sometimes two bags |
| Bowls and round containers | Container diameter and stacking height | Bag with gusset at least equal to the diameter plus clearance |
| Orders with drinks carrier | Carrier footprint | Square-base bag, or carrier handed over separately |
| Pizza | Box footprint far exceeds bag gussets | Usually carried without a bag; see custom printed pizza boxes |
How many takeaway bag sizes does a chain need?
Most chains cover their orders with two to four bag sizes: a small SOS for sides and single items, one or two mid sizes for typical meals, and a wide-base delivery bag for larger orders. A fifth size is usually only justified by a recurring order shape, such as drinks carriers.
Each extra size means extra print plates, separate production set-ups, more stock positions and another choice for staff to get wrong. Fewer, well-chosen sizes give longer runs and simpler replenishment. A typical range looks like this:
| Role | Covers | Notes |
|---|---|---|
| Small | Sides, desserts, single snacks | Often handle-less SOS; lightest grade |
| Medium | Single meals | Most-used size at the counter and drive-thru |
| Large or delivery | Two to three meals | Wide gusset, flat handles, heavier grade |
| Optional extra | Drinks carriers or family orders | Only if order data shows a recurring need |
The same discipline applies across the rest of the packaging range. The guide to reducing takeaway packaging SKUs shows how to plan boxes and bags together, and the restaurant chain packaging guide covers rolling a size range out across franchise sites.
Load, distance and paper grade
Bigger bags carry heavier orders, so size and paper grade should be decided together. A delivery bag carrying several hot meals and a drinks carrier over a twenty-minute ride needs a heavier, often wet-strength paper than a counter bag carrying a single meal to the car park.
As a rule, size the bag first, then specify the paper for the heaviest realistic order in that size, the time it spends in transit and the amount of steam and grease involved. Paper behaviour under heat and moisture is covered in grease-resistant takeaway bags.
Do your bags fit rider thermal bags?
Delivery bags spend most of their journey inside a rider's insulated bag or box. If your largest bag is too tall or too wide, riders will lay it on its side, which defeats careful base sizing.
Insulated rider bags vary by platform and courier, so measure the common ones used for your orders, or ask riders, and check that your delivery bag stands upright inside with its handles folded. A bag that is slightly lower and wider is generally more stable than a tall, narrow one.
US numbered SOS sizes and custom dimensions
US buyers often start from numbered SOS sizes such as #8 or #12. Those numbers are trade labels whose dimensions vary between converters, so use them as a starting reference and then confirm dimensions against your own layouts. The numbering system and approximate dimensions are explained in SOS bags explained. If you are having bags custom printed, you can specify dimensions around your boxes rather than the nearest numbered size, within the limits of the converter's machines.
Testing sizes before you order
Unprinted samples cost little compared with a full print run in the wrong size. Before approving dimensions:
- Pack your top order baskets into each sample size at a real packing station.
- Time the packing and watch where staff hesitate or force items in.
- Close and seal the bag using your chosen method.
- Carry it, tilt it and place it in a rider bag; check whether boxes stay level and lids stay shut.
- Repeat with the heaviest likely order in each size.
What to send for a sizing review
To get workable size proposals back, send:
- Outer dimensions (or samples) of every box, carton, container, cup and carrier that goes into a bag.
- Your most common order baskets and the largest regular order.
- Service channels: counter, drive-thru, click-and-collect, third-party delivery.
- Closure method and whether handles are needed in each size.
- Current bag sizes, if any, and what goes wrong with them.
- Approximate quantities per size.
Final dimensions are confirmed at quotation and technical review, usually after sample packing. Combine the sizing brief with the rest of your specification on the custom printed takeaway bags hub, or send it directly through the contact page.