Custom Printed Heat Seal Foil Pouches with an Open Top

How does a heat seal foil pouch work?

The pouch arrives with three edges sealed and the top edge open. You fill it, then press the open edge between the heated bars of a sealer for one to two seconds.

The inner PE layer melts and fuses to itself, making a seal that stays shut until the customer tears it. There is no zipper, so once opened the pouch is done.

That makes it the simplest style to run of all our three side seal pouches printed to size. No zipper to line up, no gusset to open, just fill and seal.

Which products suit a single-use foil pouch?

Anything eaten or used in one go. A Cornish bakery posting brownies, a Bristol roaster's 60 g taster, a Scottish smokehouse's jerky strips.

Foil also suits products that react to light. Freeze-dried fruit fades, oils in sachets go rancid, and spice blends lose colour on a sunny shelf.

Bakeries sending biscuits by post are the biggest group. Our printed cookie and biscuit bags cover that use in more detail.

• Individually wrapped biscuits, cookies and brownies
• Protein bars and flapjacks
• Single-serve coffee and tea tasters
• Freeze-dried fruit and vegetable crisps
• Sample sizes of powders and bath salts
• Face mask sheets and single-use cosmetic samples

What size heat seal pouch do I need for 50 g, 250 g or 1 kg?

Flat pouches hold less than a gusseted pouch of the same face size, because the product sits between two flat films. Allow about 30 mm of clear film above the fill line for the seal.

For a flat product like a biscuit or a bar, size to the product's footprint plus 10 mm each side. For loose products, use the table above as a starting point and we adjust on the proof.

A wide, short pouch seals faster on a bar sealer than a tall, narrow one. If you later need a self-standing version, our UK pouch size guide by fill weight gives the gusseted equivalents.

Foil, metallised or kraft: which laminate?

True aluminium foil is the layer that stops oxygen almost completely. Metallised film is a thin coating of aluminium on PET and performs well for most dry snacks at lower cost.

Food-contact, high-barrier and compostable film options are available on request, and the quote states which laminate you are getting. The laminate and barrier film guide goes layer by layer.

Tear notch, hang hole and other small details

A tear notch is a small cut in the side seal, placed just below where your top seal will be. Without it, a foil pouch is hard to open by hand and customers reach for scissors.

A round hang hole or a euro slot in the top seal lets the pouch hang on a peg. Place it before artwork is finalised so no text sits under the punch.

Rounded corners stop the pouch catching on mailer bags and reduce the chance of a corner piercing the pouch next to it.

Printing on foil: what changes?

Foil shows through any ink laid straight onto it. A red printed on bare foil looks like a metallic red, which can be a feature or a fault.

We put a white under-print beneath the colours that need to stay true, and leave the foil bare where you want a metallic effect. Your proof shows both.

Matte gold and matte silver films work well with one colour print; a black logo on matte gold is a common choice for bakeries and tea brands. Our guide to pouch artwork and dielines explains how to mark the bare foil areas in your file.

How do you heat seal foil pouches properly?

Foil laminates seal well, but the settings differ from thin clear bags. These steps avoid the two common faults, a weak seal and a wrinkled one.

1. Set the sealer to the temperature we state for your laminate, usually a little higher than for clear PE bags.
2. Fill, then shake the product down so nothing sits in the top 30 mm.
3. Wipe or brush any powder off the inside of the seal area.
4. Lay the open edge flat across the bar with no folds, and seal for the stated dwell time.
5. Let the seal cool for a few seconds before you stack the pouch.
6. Pull-test one pouch in every fifty; the film should stretch before the seal gives.

Why choose a heat seal pouch over a zipper pouch?

Cost and speed. A zipper adds material, a second seal operation and a wider top. On a 30 g sample that can be a large share of the pack price.

Tamper evidence is the other reason. A heat sealed pouch shows clearly whether it has been opened, which matters for samples sent by post.

If customers will take several servings from the pack, a zipper earns its place. Our zip lock foil bags with a press-to-close zipper are the same foil pouch with a zipper added.

Common mistakes with heat seal foil pouches

Sealing over product. A crumb or a grain of powder in the seal makes a channel for air, and the pouch looks sealed when it is not.

Ordering clear film for light-sensitive goods. If the product fades or goes rancid, choose foil and show the product on the print instead.

Running the sealer too hot. Foil laminate discolours and the seal area wrinkles, which looks poor and can weaken the film.

Leaving no plain area for a date. Put a matte white patch on the back for a stamp or a label.

Ordering heat seal foil pouches

Tell us the product, the fill weight or the dimensions, the film colour or print, and the quantity. Prices start from £0.25 per unit and every figure is confirmed on a written quote.

You get a free design proof from our team before printing. Plain unprinted foil pouches are quoted the same way, without the proof step. Send the details through the short form above, or use our contact page for phone, email and WhatsApp.

Once the proof is signed off, the run takes 4–6 business days, and free tracked UK delivery adds 2–3 business days. Report a misprint or transit damage within 10 days, with photos, and the pouches are reprinted or refunded.