Bottom gusset

A bottom gusset is a W-shaped fold sealed into the base of a pouch. When the pouch is filled, the fold opens out into an oval footprint so the pack stands up. It is the defining feature of the doypack or stand-up pouch.

How it works

During pouch making, a separate folded strip of film is inserted between the front and back panels and sealed at the sides. Empty, the pouch lies flat; filled, the weight of the product opens the gusset and the pack rests on its base.

Seal styles

• Round bottom seal: the most common style, with curved side seals, suited to light and medium fills.
• K-seal: angled seals shaped like a K that distribute weight better, preferred for heavier products.
• Plow bottom: a base folded directly from rollstock on certain machines.

Depth and design

A deeper gusset increases capacity and stability but moves some of the front panel into the base. A shallow one gives a flatter look and a less stable stance. Sizes are usually written as width × height × bottom gusset; see pouch dimensions. Keep essential artwork away from the lower edge, design on the dieline, and test filled samples for stability. The base itself can also be printed.