Pouch dimensions (width × height × gusset)

Pouch dimensions are normally written as width × height × gusset in millimetres. For example, 160 × 230 × 45 mm on a doypack can mean 160 mm wide, 230 mm tall and a bottom gusset of 90 mm when opened (2 × 45). Suppliers differ on whether they quote the open gusset or the folded half, so always confirm.

Reading the numbers

Width and height are outer dimensions including seals. The gusset is the depth of the bottom gusset on doypacks and flat-bottom pouches, or the side gusset on side-gusseted and quad-seal bags. Usable volume is smaller because of seals, the zipper and headspace.

Choosing the right size

• Think volume, not weight: 250 g of coffee beans and 250 g of ground coffee need different pouches.
• Allow space for the zipper, the seal above it, tear notches, valves and windows.
• Leave headspace for sealing and closing.
• Check shelf, display and shipping carton fit.
• Fill real samples with your product at target weight.

Common mistakes

Copying a competitor's size by weight alone, misreading the gusset, and choosing an oversized pouch that looks half empty.

Next step

Once dimensions are fixed, the converter supplies a dieline for the artwork. Changing size after design means rework, so finalise dimensions at sample stage.