Custom Printed Flat Bottom Pouches with a Square Base

What is a flat bottom pouch?

A flat bottom pouch is built from a front panel, a back panel, two side gussets and a separate base panel. Sealed together they make a pouch with a true rectangular footprint.

Filled, it stands as straight as a carton, which is why the style is often called a box pouch. Empty, the gussets fold inward and it packs flat.

The kraft coffee bags in the photos show the shape well: straight sides, a crisp base and a zipper across the top. It heads our flat bottom and quad seal bag range alongside its close relative.

Flat bottom pouch or quad seal bag: what is the difference?

Both are box shaped and both have side gussets. The difference is the base. A flat bottom pouch has a separate base panel; a quad seal bag has gussets that run to the bottom and a pinched base.

The flat bottom version stands more squarely and shows a printable base. The quad seal is cheaper and better for heavy fills where the base takes the weight. Our quad seal bags for heavier fills page covers the second column in depth.

What size flat bottom pouch holds 250 g, 500 g or 1 kg of coffee?

Whole bean coffee is light for its volume, about 0.4 g per ml, so 250 g needs around 650 ml of space. Ground coffee is denser and fits a slightly smaller pouch.

A 100 × 230 mm pouch with a 60 mm gusset is the usual 250 g coffee size. For 500 g, 130 × 270 + 80 mm; for 1 kg, about 150 × 310 + 90 mm.

Granola and muesli are lighter still, so a 500 g granola pouch is closer to the 1 kg coffee size. Our fill weight and pouch dimension guide compares these to the stand up equivalents.

Which laminate suits a box bottom pouch?

Kraft / PET / PE is the most popular for coffee and granola. The paper outer takes one or two colour print well and the PET / PE inside holds the shape.

PET / foil / PE gives the longest shelf life and a crisp metallic look under matte print. Matte BOPP / PE suits pet treats and snacks with a window.

Flat bottom pouches need a stiffer laminate than a stand up pouch so the base and sides stay square. The softer version of the kraft look is our kraft stand up pouches. Compostable, high-barrier and food-contact film options are quoted on request for this style.

Zippers, valves and tin ties

A press-to-close zipper across the top is the standard closure. A slider zipper is worth it on 1 kg and 2 kg bags that are opened daily.

For coffee packed within days of roasting, a one-way degassing valve is fitted to the front or side panel, usually in the top third. It lets carbon dioxide out and stops air going in. The timing is covered in our guide to coffee valves and degassing, including how long to rest a roast.

A tin tie is the folded-wire strip some roasters prefer for a traditional look. It replaces the zipper rather than adding to it.

Printing five panels

The front and back are the obvious panels. The two side gussets, usually 60 to 100 mm wide, carry ingredients, brew notes or a repeat pattern. The base can take a short line or a batch area.

Because the gussets are printed flat and then folded, keep text 5 mm clear of each fold. Our dieline marks every fold and seal, and the guide to preparing artwork for a printed pouch shows how to lay the panels out.

Full colour plate print makes sense on larger runs across several varieties. Digital print suits shorter runs and frequent artwork changes.

How do flat bottom pouches run on a filling line?

Pre-made flat bottom pouches are filled through the top. On a manual bench the routine is simple; automatic pouch fillers handle the same steps.

1. Open the top, then push the base and gussets out so the pouch sits square.
2. Fill by weight, keeping coffee or granola below the zipper line.
3. If the pouch has a valve, no extra step is needed; the valve is already fitted.
4. Press the zipper shut and heat seal the strip above it.
5. Stand filled pouches upright in the carton; do not lay them on the valve.

Which brands choose flat bottom pouches?

Speciality roasters wanting a premium shelf pack without a box. Granola and muesli brands selling in farm shops and delis. Pet brands moving treats from tubs to pouches.

Protein and supplement companies use them as 1 kg tub replacements, where the square base keeps the scoop upright inside. Treat makers can compare the fit against our pet food pouches with a zipper.

• Roasted coffee from 250 g to 2 kg, with a valve
• Granola, muesli and porridge oats
• Dog treats and dry cat food
• Protein powder and meal replacements
• Flour blends, rice and lentils
• Loose leaf tea in 250 g and 500 g trade sizes

Mistakes we see on flat bottom pouch orders

Ordering the base too narrow for the height. A tall, thin pouch tips when half empty; keep the gusset at least a quarter of the height.

Skipping the valve on freshly roasted coffee. The pouch bloats within a day and the seal can fail. If you pack within two weeks of roasting, add the valve.

Choosing a thin laminate to save money. The pouch slumps and the square look is lost, which was the reason for choosing the style.

Printing a side gusset with text that reads upside down once folded. Check the proof with the dieline folded in your mind, or ask us for a folded mock-up.

Ordering flat bottom pouches

Tell us the product, the fill weight, zipper or tin tie, valve or not, the laminate and the quantity. Prices start from £0.25 per unit, and the written quote fixes the figure for your run.

A free design proof from our team shows all five panels before anything prints. The quote form for printed pouches takes your artwork files too. With the proof approved, the pouches are produced in 4–6 business days.

Free tracked delivery across the UK follows in 2–3 business days. Any misprint or damage you report within 10 days, with photos, is put right with a reprint or a refund.