Pouch Packaging Glossary

3 side seal pouches use space efficiently and work well for small portions, samples and flat products. Zippers, tear notches and hang holes can be added when the specification allows them.

Common uses include:

• Samples and 1 portion packs
• Powders, components and flat products

The gusset style and depth affect stability, usable volume and the amount of film required. Doyen, K seal and plough bottom are 3 gusset constructions used for different weights and formats.

Common uses include:

• Stand up pouches
• Spout pouches

Custom print gives you control over branding, product information and finish. The right print method depends on quantity, artwork, lead time and how often the design changes.

Common uses include:

• Retail product ranges
• Seasonal and multiple design runs

Flat bottom bags make efficient use of shelf space and provide front, back, side and base panels. Coffee and higher-value dry products often use this format because it holds its shape well.

Common uses include:

• Coffee beans
• Tea, snacks and pet food

Flat pouches use little material and are easy to store or post. They suit smaller fill weights, samples and products that don't need to stand upright on a shelf.

Common uses include:

• Samples and refills
• Small parts and powdered products

Flexible packaging normally uses less storage space than rigid tubs, jars or bottles. Custom printed pouches still need a film structure that matches the product, filling method and required barrier, so low pack weight shouldn't be the only reason for choosing them.

Common uses include:

• Pouches and sachets
• Roll stock for packing machines

Bottom filling protects finished top features and can provide a wide opening. The bottom seal still needs the correct temperature, pressure and time for the pouch structure.

Common uses include:

• Pouches with finished top closures
• Manual and semi-automatic filling

Open top pouches work for manual or semi-automatic filling. The opening width, product cleanliness and sealing conditions all affect whether a reliable final seal can be made.

Common uses include:

• Dry foods and powders
• Small production runs

Roll stock suits automated packing at higher speeds. The reel width, repeat length, sealing layer, print registration and machine direction must match your packing equipment.

Common uses include:

• Sachets and pillow packs
• Vertical and horizontal packing machines

The material must suit the product and the intended opening method. Sachets can be supplied pre-made or formed from roll stock on automated filling equipment.

Common uses include:

• Condiments and powders
• Cosmetics and product samples

A custom shape needs enough seal area to run through production and filling safely. Complex outlines can affect material use, tooling and how the pouch stands or hangs.

Common uses include:

• Promotional ranges
• Products needing a distinct outline

Side gussets can suit dense products and larger fill weights. Their dimensions affect the finished pack width, stability and available print area.

Common uses include:

• Coffee bags
• Larger dry product packs

Side gusset bags are common for coffee and other dense dry goods. They pack neatly, work with degassing valves and allow several top closure options to suit the filling process.

Common uses include:

• Coffee
• Bulk dry products

Spout pouches suit products that need controlled pouring and resealing. Check the film, spout and seal against the liquid, alcohol content, filling temperature and transport conditions.

Common uses include:

• Drinks and sauces
• Refills and liquid household products

Stand up pouches give a wide front panel for printed information while packing flat before filling. They suit dry goods, powders and many other products when the material and closure match the contents.

Common uses include:

• Coffee and tea
• Snacks, supplements and pet treats

Stock pouches work well for trials, urgent orders and businesses that don't need a fully bespoke structure. You can often buy them in lower quantities and fill them as soon as they arrive.

Common uses include:

• Product trials
• Short runs and urgent orders

Foil pouch packaging gives strong protection but removes product visibility and can affect recycling routes. Small pinholes or damage can reduce performance, so thickness and handling matter.

Common uses include:

• Long-shelf-life dry products
• Light and aroma-sensitive contents

Choose the barrier around the problem that shortens the product's shelf life. Coffee needs aroma and oxygen protection, while a moisture-sensitive powder may need stronger protection against water vapour.

Common uses include:

• Food, coffee and supplements
• Products sensitive to moisture or oxygen

BOPP is used for clear, white and metallised packaging films. It doesn't normally heat seal in the same way as a dedicated inner sealant unless it has a suitable coating or layer.

Common uses include:

• Snack and confectionery film
• Printed laminate outer layers

EVOH gives a strong oxygen barrier but its performance can fall when exposed to moisture. The surrounding layers protect it and help determine the oxygen barrier of the finished pouch.

Common uses include:

• Oxygen-sensitive foods
• Barrier monomaterial structures

Each layer does a different job, such as carrying print, adding stiffness, blocking light or forming the heat seal. Changing one layer can affect recycling, barrier, filling and shelf life.

Common uses include:

• Packaging specifications
• Barrier and seal selection

High barrier doesn't mean the same construction for every product. Aluminium, EVOH and metallised layers behave differently, so the target shelf life and storage conditions need to be understood first.

Common uses include:

• Coffee and aroma-sensitive products
• Longer shelf life dry goods

Kraft pouches aren't automatically paper-only, recyclable or compostable packaging. The inner films, adhesives, coatings and disposal instructions need to be checked.

Common uses include:

• Coffee, tea and dry food pouches
• Kraft overprinted stock pouches

A laminate may combine a printable outer film, a barrier middle layer and a heat-seal inner layer. The bonding process and adhesive must suit the intended food-contact and filling conditions.

Common uses include:

• Printed pouches
• Multi-layer barrier structures

Metallised film isn't the same as solid aluminium foil. It can provide a metallic appearance and useful barrier, but exact performance depends on the coating and complete laminate.

Common uses include:

• Coffee and snack packaging
• Metallic printed pouch finishes

Using 1 polymer family can make a pouch more suitable for an established recycling stream. Barrier, stiffness, print and sealing still need to meet the product specification.

Common uses include:

• Recyclable pouch projects
• Dry foods and refills where the structure fits

Polyamide can suit liquids, sharp-edged products and pouches that may be dropped, flexed or squeezed. Moisture can affect its properties, so it usually sits within a multi-layer structure.

Common uses include:

• Spout pouches
• Puncture-resistant laminates

PE can also form most of a monomaterial pouch. The exact grade affects puncture resistance, sealing range and suitability for soft plastic recycling routes.

Common uses include:

• Sealant layers
• PE-based recyclable pouches

PET is commonly reverse printed and laminated to a sealant or barrier layer. It shouldn't be confused with PE, which normally performs a different job in the structure.

Common uses include:

• Printed outer layers
• PET/ALU/PE laminates

The sealant must suit the pouch material, product, filling temperature and sealing equipment. Contamination in the seal area can prevent a complete bond.

Common uses include:

• Heat-sealed pouches
• Roll stock packing

A centre spout affects the top seal and filling method. Cap size, neck diameter and product viscosity need to match how the pouch will be used.

Common uses include:

• Drinks and gels
• Sauces and liquid refills

Corner spouts are common on larger liquid packs and products poured into another container. Spout size and film strength need to suit the product and filled weight.

Common uses include:

• Liquid refills
• Sauces and larger drink packs

Coffee pouch packaging must deal with the carbon dioxide released by roasted beans after packing. The valve releases pressure while the bag stays closed, which protects aroma and reduces pack swelling.

Common uses include:

• Whole bean coffee
• Freshly roasted ground coffee

Euro slots suit display hooks and rails used in many shops. The top seal area needs enough height and strength to support the filled pouch safely.

Common uses include:

• Retail accessories
• Small food and product packs

The opening diameter controls flow, while the hinge and closure need to remain secure through transport and repeated use. Product viscosity is an important part of the choice.

Common uses include:

• Gels and drinks
• Personal care liquids

The film and seal area around the hole need enough strength to carry the filled pack. Hole position also needs to avoid zippers and final sealing areas.

Common uses include:

• Small retail pouches
• Light products displayed on hooks

Laser scoring can create cleaner opening lines and shaped tear paths. Depth must be tightly controlled so barrier and seal performance aren't damaged before opening.

Common uses include:

• Easy-open pouches
• Controlled tear shapes

Pocket zippers are often used on larger flat bottom bags and retail packs. Their position affects artwork, filling and how much of the product can be reached.

Common uses include:

• Large pet food bags
• Flat bottom retail packs

The surrounding structure needs enough strength for the filled weight. A handle also changes the available print area and may affect the final seal position.

Common uses include:

• Large pouches
• Heavy or pourable products

Windows help show texture, colour and fill level, but they reduce light protection. Products that fade or oxidise under light may need a smaller window or an opaque structure.

Common uses include:

• Snacks and confectionery
• Craft and natural products

Resealable pouches help contain a product after first opening, but the zipper isn't a substitute for the initial heat seal. Profile size and position need to match the pouch and contents.

Common uses include:

• Coffee, snacks and powders
• Products used over several occasions

Corner radius must leave enough seal width and work with the pouch shape. It's a finishing choice, not a substitute for checking edge and seal strength.

Common uses include:

• Retail pouches
• Packs handled directly by customers

Thread design, tamper evidence and cap material need to suit the application. Larger openings pour faster but use more space and can be harder to control.

Common uses include:

• Sauces and drinks
• Cleaning and refill products

Notch position matters. It must help the tear start without cutting through the zipper, reducing the final seal area or opening the pouch before sale.

Common uses include:

• Sachets
• Resealable and heat-sealed pouches

Top sliders can be easier to handle than a press-to-close zipper, especially on larger pouches. They add components and need enough space at the top of the pack.

Common uses include:

• Large dry food packs
• Products opened frequently

A PDF proof checks content and position but can't always predict exact material colour or finish. Physical and press proofs provide more information but add time and cost.

Common uses include:

• Final artwork approval
• Checking variants and legal copy

CMYK is well suited to photographs and artwork with many colours. Some brand colours can fall outside its printable range and may need a separate Pantone colour.

Common uses include:

• Photographic pouch artwork
• Multi-colour designs

The dieline isn't printed as part of the finished design. Text and important graphics need to stay inside safe areas and away from seals, notches and other features.

Common uses include:

• Artwork setup
• Custom pouch dimensions

Digital printing suits shorter runs, several designs and artwork that changes regularly. Colour, material choice and finishing options still need to be confirmed against the press and pouch structure.

Common uses include:

• Launches and seasonal ranges
• Multiple flavours or designs

The film structure and pouch position need enough stability for the pressed detail. Embossing close to seals, zippers or folds can be difficult to control.

Common uses include:

• Logos and patterns
• Tactile packaging details

Flexographic printing is often compared with digital and gravure printing. Polypouch doesn't currently offer flexographic printing, but knowing how it works can help you compare packaging quotations and specifications.

Common uses include:

• Packaging film and labels
• Medium and longer print runs

Gloss can make photographic artwork appear crisp and saturated. Reflections, fingerprints and the contrast with uncoated areas need to be considered.

Common uses include:

• Colourful retail artwork
• Clear and metallised pouches

Gravure produces consistent detail across long runs and works with many film types. Cylinder production adds setup work, so it normally makes more sense when quantities are higher and artwork is settled.

Common uses include:

• Longer production runs
• Detailed custom pouch artwork

Overprinting can suit lower quantities and shorter lead times than fully manufactured custom film. The existing pouch size, material, colour and features stay fixed.

Common uses include:

• Short branded runs
• Simple logos and one-off ranges

Matt surfaces change colour appearance and can show scuffs differently from gloss. The finish should be checked with the print method and any spot effects.

Common uses include:

• Coffee and premium dry goods
• Designs needing low reflection

Foiling can draw attention to logos or small design details. Material, artwork area, fold position and production process determine which effects are practical.

Common uses include:

• Logos and limited design accents
• Gift and seasonal packaging

Pantone references help communicate a target brand colour. The final appearance still changes with film colour, finish, opacity and the printing process.

Common uses include:

• Brand colours
• Solid areas needing close colour control

Cylinder depth and engraving affect ink coverage and detail. Cylinders are made for the approved artwork, so later design changes can require new tooling.

Common uses include:

• Gravure printed pouch film
• Long repeat production

Print-ready files normally need embedded or outlined fonts, suitable image resolution, correct colours, bleed and an approved dieline. Polypouch still checks technical suitability before production.

Common uses include:

• Custom print orders
• Artwork handover

Poor registration can create coloured edges, blurred details or artwork that moves towards a seal. Tolerances matter when designs use fine text and tight colour trapping.

Common uses include:

• Multi-colour printing
• Roll stock and repeated designs

Plate quality affects edges, small text and colour alignment. Artwork changes can require new plates, unlike digital printing.

Common uses include:

• Flexographic printing
• Some stock pouch overprinting

The outer film protects the ink from rubbing and contact. Artwork and colour order need to be prepared correctly because the image is printed in reverse before lamination.

Common uses include:

• Printed PET laminates
• Gloss and matt pouch structures

Soft touch needs handling and rub checks because coatings can mark or change the way colours appear. It also needs compatibility with other effects such as spot gloss.

Common uses include:

• Higher-value retail ranges
• Matt designs with tactile contrast

The gloss needs accurate registration with the printed artwork. Fine lines and areas close to folds or seals may need adjustment to stay consistent.

Common uses include:

• Logos and product names
• Patterns and highlighted details

Every Polypouch pouch is food grade certified as a minimum, including pouches intended for non-food products. Before ordering food pouch packaging, test the pouch with your product and filling process to confirm it works for your application.

Common uses include:

• Food, drink and supplement packaging
• Direct product contact

A good seal depends on clean film surfaces, suitable jaws and the correct settings for the sealant layer. Too little heat can leave weak areas, while too much can distort the film.

Common uses include:

• Closing pre-made pouches
• Forming packs from roll stock

Hot fill temperature and contact time can soften or distort unsuitable films. Test cooling time, headspace and cap application as part of the packing trial.

Common uses include:

• Sauces and prepared foods
• Some liquid spout pouch products

Impulse sealers suit many manual packing operations and pre-made pouches. Bar width, seal length and machine rating need to match the film and opening size.

Common uses include:

• Small and medium packing runs
• Open top stock pouches

OTR helps compare structures for oxygen-sensitive products, but the value only makes sense alongside temperature, humidity, thickness and test method. Finished pack seals also affect performance.

Common uses include:

• Coffee and food packaging
• Shelf life assessment

Product density, particle size, trapped air, headspace and closure position all change the usable fill. Physical filling trials give a better answer than nominal dimensions alone.

Common uses include:

• Choosing pouch dimensions
• Comparing samples

Product formulation, processing, oxygen, moisture, light, temperature and the final seal all affect shelf life. Film choice should be supported by product testing rather than guesswork.

Common uses include:

• Material specification
• Storage and distribution planning

Tamper evidence helps users recognise first opening, but it isn't the same as child resistance or full security. The feature needs to remain visible and intact through transport.

Common uses include:

• Food and supplement pouches
• Retail packs with resealable zippers

WVTR matters for powders, crisp foods and products that dry out or absorb moisture. Test temperature and humidity must be considered when comparing results.

Common uses include:

• Powders and dry foods
• Moisture-sensitive products

Bio-based doesn't automatically mean biodegradable or compostable. Some bio-based PE enters the same recycling route as fossil-based PE, subject to local collection rules.

Common uses include:

• Renewable feedstock packaging
• PE-based pouch structures

Biodegradable and compostable aren't interchangeable claims. You need evidence covering the exact material and intended disposal environment before placing the term on-pack.

Common uses include:

• Technical material discussions
• Comparing environmental claims

Compostable doesn't mean the pouch can be placed in any compost or left in the environment. Product barrier needs and access to the correct waste route must be checked.

Common uses include:

• Selected dry products
• Projects with a suitable composting route

The material normally won't break down in the same way in an ordinary garden compost heap. Collection access and clear labelling matter because the correct facility may not be available locally.

Common uses include:

• Certified compostable structures
• Products with an identified collection route

PCR content can reduce demand for virgin plastic, but colour, odour, consistency and food-contact restrictions need checking. State the percentage and source accurately.

Common uses include:

• Non-food and selected approved applications
• Recycled content claims

Recyclability depends on the complete pouch structure, the market and the collection system available. Polypouch's recyclable pouches are certified for their stated recycling route, but you still need disposal instructions that match the market where the pouch will be sold.

Common uses include:

• PE and PP based pouch structures
• Products using soft plastic collection routes

A resin identification code describes the plastic family; it doesn't certify that the finished pouch will be accepted for recycling. Polypouch's eco-friendly pouch range includes certified recyclable options using codes 4, 5 and 7. Check the complete structure, intended market and available collection route before making an on-pack claim.

Common uses include:

• On-pack recycling information
• Supermarket soft plastic collection