Guide
Pouch Sizes Explained
Pouch size is set by the volume your product occupies, not by its weight, so start from density. Width and height give you the printable face; the bottom gusset gives you the depth that actually holds the fill. As a working reference, 180 × 260mm with a 60mm gusset holds roughly 500g of ground coffee, 250g of granola, or 400g of protein powder.
How pouch dimensions are written
Pouches are quoted as width × height, then gusset. 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.
Two pouches with the same width and height can hold very different amounts if their gussets differ. If you are comparing quotes from different suppliers, check the gusset — it is the number most often left out.
Common sizes by product
These are practical starting points rather than fixed options. Custom sizes are available and usually cost no more than a standard one, because the dieline is made for your job either way.
- Sample sachet — 60 × 90mm, no gusset
- 100g snack — 120 × 190mm, 50mm gusset
- 250g coffee — 130 × 225mm, 70mm gusset
- 500g granola — 200 × 300mm, 80mm gusset
- 1kg protein powder — 200 × 320mm, 100mm gusset
- 2kg pet feed — 250 × 380mm, 110mm gusset
Allow headspace
Never size a pouch to exactly the volume of the product. You need headspace above the fill so the top can be sealed cleanly, and a zip needs more clearance than a plain seal. Around 15–20% headspace is a sensible allowance, more if you are filling by hand.
If you are filling on an automated line, the machine's own tolerances also matter. Tell us the filler model when you enquire and we will check the pouch works with it.
The reliable way to get it right
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. This takes five minutes and removes the guesswork entirely — it is far more accurate than working from a size chart.
Related questions
Quick answers
- What size pouch do I need for 250g of coffee?
- Around 130 × 225mm with a 70mm gusset. That holds 250g of whole bean with enough headspace to seal, and a little more if you are packing ground coffee, which is denser.
- Can I order a custom pouch size?
- Yes, and it rarely costs more than a stock size, because a dieline is produced for your job either way. Give us the fill volume and we will work back to dimensions.
- What does the gusset measurement mean?
- It is the depth of the folded base when the pouch opens out and stands. It determines how much the pouch actually holds, which is why two pouches with identical width and height can have very different capacities.
- How much headspace should I leave?
- Around 15–20% of the pouch volume. You need room above the fill to make a clean top seal, and a zip closure needs more clearance than a plain heat seal.
Still have questions? Email hello@thepouchworks.com and we'll get back to you within one business day.