Custom Lay Flat Pouches
Custom lay flat pouches — three-side-seal and pillow pouches that lie flat for sachets, samples and single serves — in barrier or recyclable mono-material film, printed with your brand, from 100. Spec and price the same working day.
The flat pouch is the sample, the sachet and the single serve
- Film
- Laminated barrier (PET/AL/PE, PET/PE); mono-material PE or PP; paper-faced
- Formats
- Three-side-seal, pillow, zip-top flat, tear-notch
- Sizing
- Fill plus 10 mm each way; seals 5–8 mm; hang hole optional
Get a price for Lay Flat Pouches
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Four sealed shapes that lie flat
| Three-side-seal | Sealed on three sides, filled, sealed on the fourth; the sachet standard |
|---|---|
| Pillow pouch | A tube sealed top and bottom with a back seam; the snack-bag format |
| Zip-top flat pouch | A three-side-seal with a zipper; reclosable |
| Tear-notch pouch | A notch for a clean tear; single serves |
What goes in a flat pouch
- Sachets of powder, liquid, cream or gel — supplements, sauces, cosmetics samples.
- Single-serve coffee, tea, sweetener, spice.
- Small dry goods — seeds, beads, hardware, a card.
- Face masks and wipes.
- A sample of anything, posted in a letter.
Film: barrier or mono-material
A laminated film — PET/AL/PE or PET/PE — gives a barrier against oxygen, light and moisture for a product with a shelf life. A mono-material PE or PP film recycles as a soft plastic and suits a dry product sold quickly. A paper-faced laminate gives a paper look with a film inside. The film is chosen from the product and the shelf life. Our pouches in every format and film cover the stand-up and gusseted versions.
Sizing and seals
A flat pouch is sized to the fill: the product plus 10 mm each way for the seals and a little room. Seal width 5–8 mm; a tear notch above the fill; a hang hole above the seal for a peg. Liquids and creams need a wider seal and a film that seals through contamination; powders need a seal that does not trap dust.
Send the fill weight and a sample of the product. A sachet of cream and a sachet of powder the same size seal differently.
Print, and the very short run
Flexo or digital in full color on the outside face, matte or gloss; a white underprint on clear film. Digital print makes a run of a hundred sachets of one design affordable, and a set of five designs in one order costs the same per pouch. The regulatory text — ingredients, batch, allergens — is reserved on the back.
Lay Flat Pouches — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Film
- Laminated barrier (PET/AL/PE, PET/PE); mono-material PE or PP; paper-faced
- Formats
- Three-side-seal, pillow, zip-top flat, tear-notch
- Sizing
- Fill plus 10 mm each way; seals 5–8 mm; hang hole optional
- Flexo or digital full color; white underprint; matte or gloss
- Fill
- Powder, liquid, cream, gel, dry goods; seal specified to the fill
- Regulatory
- Panel reserved on the back
- Minimum
- 100 pouches
On every job
- Print process
- Flexo in up to ten colors on the outer film, or digital for short runs and changing artwork.
- Color
- A white underprint carries normal color on metallised or clear film. Without it, every color takes on what is beneath it.
- Tolerance
- Bag width plus or minus 2 mm, length plus or minus 3 mm. Film stretches, so a barcode is verified on a filled bag.
- Tooling
- Print plates or cylinders per design, kept. There is no cutting die — the bag is formed and sealed rather than cut.
- Food contact
- A food-grade sealing layer against the product, with the inks trapped between layers rather than on the food face.
- Sustainability
- Mono-material PE or PP where the shelf life allows, which recycles as a soft plastic. A foil laminate does not.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build lay flat pouches on
A flexible pack is a stack of films laminated together, and the middle layer is the barrier. The structure is chosen from the shelf life you need and what you want to be able to say about recycling.
PET / PE
A printable outer and a sealing inner. Moisture barrier, modest oxygen barrier. The everyday laminate for dry goods sold quickly.
2-ply, 70–110 micronPET / AL / PE
Aluminum foil in the middle: the strongest barrier against light, oxygen and moisture. Coffee, supplements, anything with a long shelf life.
3-ply, 90–130 micronMetallised PET
A vapour-deposited metal layer. Bright, lighter and cheaper than foil, with a weaker barrier. Most silver and gold bags are this.
2–3 plyMono-material PE
Every layer polyethylene, so the bag recycles as a soft plastic. Less barrier and a slightly softer hand; the sustainable choice where shelf life allows.
100–130 micronMono-material PP
Stiffer and clearer than PE, with better heat resistance. Suits a stand-up pouch that has to hold its shape on a shelf.
90–120 micronKraft-paper laminate
A paper outer over a film barrier. The natural look with a real barrier behind it; the paper takes only a matte, flat print.
Paper 60–80gsm + filmCompostable film
PLA and cellulose structures certified for industrial compost. Lower barrier, higher cost, and no home-compost claim unless the certificate says so.
60–90 micronLDPE mailer film
Co-extruded opaque film for shipping bags: tear- and puncture-resistant, weatherproof, and recyclable where soft plastics are collected.
60–80 micronNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Film is finished in the lacquer and the ink, not with a laminate.
Matte lacquer
A soft, non-reflective face. Hides handling marks and the most-used finish on a premium pouch.
Gloss lacquer
Wet-looking color. Reads cheaper on some categories and exactly right on confectionery.
Spot matte on gloss
A matte shape on a gloss field, or the reverse. The film equivalent of spot UV.
Metallised effects
Print over the metal layer so a color picks up the shimmer, or lay white under it for a normal color.
Registered emboss
A raised texture pressed into the film. Rare, expensive, and unmistakable in the hand.
Kraft-paper face
A paper outer laminated to the barrier. Matte and flat by nature; no varnish needed.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a pouch by what goes in it, not by a bag size: lay flat pouches
Film packs are specified by fill, not by dimensions. Two products of the same weight can need very different bags, because density decides volume — whole coffee beans take far more room than the same weight of powder.
- Fill weight and density
- Give us both, or send the product. We size from the volume it actually occupies, settled.
- Lay-flat width
- Half the circumference of the finished bag. It is the number a converter works to, and we calculate it from your product.
- Headspace
- Enough film above the fill to seal cleanly and for the bag to stand. Too little and the seal traps product; too much and the pack looks underfilled.
- Gusset
- Bottom gusset depth sets how the bag stands; side gussets add volume without width. Both are chosen from the shelf, not the fill.
- Seal width
- 5–8 mm. Wider on liquids and creams, which contaminate a seal, and on anything that will be posted.
- Sample fill
- A plain bag at the finished size, filled from your line, is the only reliable check before print.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Spec your Lay Flat Pouches
Pick a shape, type a size, choose a film and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about lay flat pouches? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What is a lay flat pouch?
Two sheets of film sealed on the edges with no gusset or base, so it lies flat. It is the sachet and single-serve format.
Can it hold liquid?
Yes, with a wider seal and a film that seals through contamination. Send a sample of the product.
Is there a recyclable option?
Yes, a mono-material PE or PP film for dry products sold quickly. Barrier laminates are for shelf life.
Can it have a zipper?
Yes, a zip-top flat pouch for a reclosable pack.
What is the minimum order?
100 pouches.
Can I print several designs in one order?
Yes, digitally, at the same price per pouch.
Can it hang on a peg?
Yes, with a hang hole above the seal.
Is it food safe?
Yes, in the food-grade film and ink specification.
Can it go through a letterbox?
Yes, a flat pouch in a card mailer is the sample-by-post format.
Where does the ingredients text go?
On the back, in a reserved panel.
Can I have a tear notch?
Yes, above the fill, for a clean single-serve open.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
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