Pouch Size Guide: What Size Pouch Do I Need?

Pouch sizes are written as width × height × gusset, in millimetres. Width is the flat measurement across the front panel, height runs from the bottom fold to the top of the seal, and the gusset is the depth of the folded base when it opens out.

A pouch described as 180 × 260 × 60mm is 180mm wide, 260mm tall and 60mm deep at the base. If a supplier quotes only two numbers, the gusset is missing — and that is the number that decides how much the pouch actually holds. Our custom printed stand-up pouches are made to your dimensions, so the chart below is a starting point rather than a fixed range.

A pouch gusset is the folded section at the bottom of a stand-up pouch that expands when filled, increasing capacity and helping the pouch stand upright.

Because the gusset adds depth, it has a bigger effect on capacity than height does. Two pouches at 180 × 260mm can differ by 200g of fill if one has a 40mm gusset and the other 80mm. A deeper gusset also gives a wider base, which makes the pouch more stable on shelf — useful for tall formats that would otherwise topple. Flat pouches have no gusset at all; see stand-up vs flat pouch for how that changes format choice.

The sizes below are indicative dimensions for a stand-up pouch, based on typical densities for each product. Treat them as a working starting point.

For 100g, a stand-up pouch of around 120 × 190mm with a 50mm gusset is a sensible starting point.

That works for medium-density products such as coffee, spices and sweets. A light, bulky product — puffed snacks, dried herbs, loose leaf tea — takes up more volume per gram and usually needs a taller pouch at the same width, closer to 130 × 210mm.

For 250g, around 130 × 225mm with a 70mm gusset suits most dense products.

That covers ground and whole bean coffee, protein powder and pet treats. Granola and similar bulky products at the same weight typically need 160 × 250mm with an 80mm gusset, because they occupy roughly twice the volume.

For 500g, around 180 × 260mm with a 60mm gusset is the usual reference size.

This is a well-proven 500g coffee format. For lighter products, increase the height before the width — a taller pouch keeps the shelf footprint the same while adding volume. If you are adding a zip, allow another 15–20mm of height for the closure.

For 1kg, around 200 × 320mm with a 100mm gusset is a practical starting point.

At this weight the base does the work, so the gusset matters more than at smaller sizes. A shallow gusset on a 1kg pouch produces a tall, unstable pack that leans forward on shelf. Heavier fills also need a thicker film and a wider bottom seal so the pouch survives handling and transit.

Product density is the weight of your product per unit of volume. A pouch holds volume, not weight, so density decides how much of a given product fits.

This is why 250g of three products can need three different pouches. Ground coffee is dense and settles tightly, so it fills a compact pouch. Sweets are irregular and trap air between pieces, so the same weight takes noticeably more room. Protein powder is fine and dense but aerates during filling, then settles — so it needs headspace at fill that disappears on shelf.

Headspace is the empty space above the product once the pouch is filled. Allow around 15–20% of the pouch volume.

You need it for three reasons: the top seal must close on clean, product-free film or it will fail; a zip sits below the seal and needs clearance above the fill to open and close properly; and hand filling is less precise than machine filling, so a manual line needs more margin. Products that settle, such as powders and granola, look under-filled on shelf if you allow too much — test with the real product before committing to a size.

Weigh out your actual product into a measuring jug and note the volume it occupies. Send us that volume with your target fill weight and we will convert it into dimensions, then produce a dieline for your job. This takes five minutes and is far more accurate than working from any chart, including this one.

Custom sizes rarely cost more than a standard one, because a dieline is produced for your run either way. Get my pouch quote and tell us what you are packing, and we will size it with you.