How to Choose a Stand-Up Pouch Size by Fill Weight and Density

The question we hear most often about stand-up pouches is “what size do I need for 250 grams?” The honest answer is that it depends on the product. 250 g of whole coffee beans and 250 g of granulated sugar will not fit the same pouch, because they take up very different volumes. This guide explains how to choose a doypack size from your fill weight and product density, how the dimensions are written, and what to check before you order.

Reading a pouch size: width, height and bottom gusset

Stand-up pouch sizes are usually given in millimetres as width × height + bottom gusset. A pouch listed as 130 × 220 + 35 mm is 130 mm wide, 220 mm tall and has a bottom gusset that is 35 mm deep when folded.

• Width is measured from outer edge to outer edge. The side seals sit inside this figure, so the usable inner width is a few millimetres less.
• Height runs from the lowest point of the base to the top edge. The zipper, tear notch and top seal all live within it.
• Bottom gusset is the depth of the W-shaped fold in the base. It opens out once the pouch is filled and becomes the footprint the pack stands on. See the bottom gusset entry for more detail.

A deeper gusset adds volume and makes the pouch more stable on the shelf. The trade-off is that the gusset eats into the overall height, so a deep gusset on a short pouch leaves you less front panel for your design.

Volume matters more than weight

What fills a pouch is volume, not grams. That is why you need to know your product's bulk density: how many grams it weighs when poured into a one-litre container. Typical figures look like this:

• Crisps and puffed snacks: about 80 g per litre
• Loose tea: about 300 g
• Whole coffee beans: about 380 g
• Granola and muesli: about 400 g
• Ground coffee: about 420 g
• Nuts, flour and food powders: about 550 g
• Rice, pulses and sugar: about 820–850 g

Real values shift with particle size, moisture and how much the product settles during filling. A nut mix heavy on cashews will not behave like one heavy on hazelnuts. Treat any table as a starting point; a trial fill gives you the real answer.

Typical stand-up pouch sizes and what they hold

The table below lists our standard doypack sizes with a recommended fill for four common products. These are comfortable fills where the pouch closes easily and stands well; every size also has a lower and an upper limit.

One pattern stands out straight away. For 250 g of whole beans, 130 × 220 + 35 is right at the edge and the next size up is often the safer choice, while 250 g of rice sits happily in a 110 × 185 + 35 pouch. Our pouch sizes entry covers the full range, including other pouch styles.

When another format makes more sense

A doypack works well for most dry products up to about a kilo, but it is not always the best fit:

• Coffee from 250 g upwards: a flat bottom pouch stands like a carton and holds the same weight in a slimmer, taller body. A 115 × 215 + 40 mm flat bottom takes roughly 250–325 g of beans and gives you five printable panels.
• Heavy fills and 1 kg coffee: a quad seal pouch keeps its shape under weight thanks to its four corner seals. 145 × 400 + 40 mm is a typical choice for a kilo of beans.
• Very light, bulky products: low-density snacks push you into an oversized stand-up pouch, and a pillow pack is usually cheaper.

A practical way to work out your size

If you are starting from scratch, this method gets you close:

• Measure density. Fill a one-litre measuring jug with your product, tap it gently to settle and weigh it. That figure is your approximate bulk density.
• Work out volume. Divide the target weight by the density. 500 g of a product that weighs 550 g per litre needs roughly 0.9 litres.
• Add headroom. Leave space for the zipper, the top seal and an easy close. The product should stop a few centimetres below the zip.
• Compare. Check your figure against the table, or pick your product and weight in the price calculator to see suggested sizes.
• Trial fill. Ask for blank samples in your chosen size plus one size either side, and fill them with the real product.

What to check during a trial fill

A trial fill is where the maths meets reality. As you fill the sample pouches, look at the following:

• Does the pouch stand on its own on a flat surface, or does it tip forwards or backwards?
• Does the zipper close without strain, and does product creep into the zip track?
• Is there clean space for the top seal? Powder or crumbs in the seal area are a common cause of leaks.
• Does the key part of your design sit where the filled pouch bulges and distorts?
• For coffee, is the degassing valve above the product level?

If you fill on a machine, find out its accepted range for width, height and mouth opening before you commit. A size that works by hand can still cause trouble on a line.

Common mistakes

• Copying someone else's size. A 500 g granola pouch is far too big for 500 g of lentils.
• Ignoring the gusset. Looking only at width and height leads to poor volume estimates.
• Filling to the brim. Overfilling causes seal failures and zips that pop open. Aim for the recommended fill, not the maximum.
• Finishing the artwork first. Artwork made before the size is fixed usually has to be reworked once the dieline arrives.
• Using one size for every weight. If 250 g and 500 g share a pouch, one looks half empty and the other struggles to close.

Not sure which size fits? Tell us your product, target weight and how you fill, and we will suggest sizes to test. You can reach us through the contact page.