Tool
Pouch size calculator
Pouch capacity is a volume, not a weight, so the size you need depends on how dense your product is. Pick your product and fill weight below and this calculator converts the weight to volume, adds 20–25% headspace for sealing and standing, and returns the pouch size we would specify — width × height × gusset in millimetres.
Work out your size
250g of coffee — whole bean occupies about 658ml. With headspace you need roughly 822ml of usable capacity.
140 × 230 × 70mm
Recommended stand-up pouch — approximately 1024ml usable capacity.
Densities are indicative averages. Granola from two suppliers can differ by 20%, so we always confirm against a real sample before a run prints.
How the calculation works
Step one converts weight to volume: fill weight in grams divided by bulk density in grams per millilitre. Bulk density is the poured density of the product including the air between the pieces, which is why nuts and crisps behave so differently at the same weight.
Step two adds headspace. A pouch filled to its absolute capacity cannot be sealed cleanly and will not stand, so we allow roughly 20–25% on top.
Step three picks the smallest standard size whose usable capacity covers that figure. Usable capacity is less than the raw box volume, because a filled pouch is a rounded shape and the top 40mm is taken by the seal and any zip. The full reasoning is in pouch sizes explained.
Common fill weights and the sizes that suit them
| Fill weight | Typical products | Indicative size (W × H × gusset) |
|---|---|---|
| 50g | Loose leaf tea, ground spices, samples | 80 × 130 × 40mm |
| 100g | Tea, spice blends, capsule supplements | 100 × 150 × 50mm |
| 250g | Coffee, granola, nuts, protein samples | 140 × 230 × 70mm |
| 500g | Coffee, cereal, dried fruit, pet treats | 160 × 250 × 80mm |
| 1kg | Protein powder, rice, grains, dry pet food | 200 × 300 × 90mm |
| 2kg+ | Bulk grains, dry pet food, wholesale packs | 230 × 340 × 100mm |
Related reading
Pouch sizing — quick answers
How do I work out what size pouch I need?
Divide the fill weight in grams by the product's bulk density in grams per millilitre to get the volume it occupies, add roughly 20–25% headspace so the pouch can be sealed and stand properly, then choose a pouch whose usable capacity covers that figure. The calculator on this page does all three steps for you.
What size pouch holds 250g of coffee?
Whole bean coffee has a bulk density near 0.38 g/ml, so 250g occupies about 660ml, and with headspace you need roughly 800ml of usable capacity. A stand-up pouch around 140 × 230 × 70mm is the usual answer, and a degassing valve is essential for freshly roasted coffee.
Why does the same size pouch hold different weights?
Because capacity is a volume, not a weight. A pouch that holds 1kg of rice holds only about 200g of crisps, since crisps are around five times less dense. Always size from volume and then check with the real product.
How much headspace does a pouch need?
Around 20–25% of the total volume. A pouch filled to the brim cannot be sealed cleanly, does not stand well, and stresses its seals in transit.
Can you confirm the size before I order?
Yes. Send your spec through the builder with the product and target weight and we will confirm the size we would use and quote it within one business day. Minimum order is 100 units per design.
Still have questions? Email hello@thepouchworks.com and we'll get back to you within one business day.