Pouch sizing confuses people because a pouch is a flexible object described by flat measurements. A pouch that measures 5 by 8 with a 3 inch gusset does not stand 8 inches tall when it is full, and it does not hold a predictable weight. Here is how the numbers work.
The three numbers
- Width. Measured flat across the face of the pouch, seal edge to seal edge.
- Height. Measured flat from the base to the top edge, usually including the top seal area. Ask whether a quoted height includes the zipper track, because that changes usable space.
- Bottom gusset. The folded panel at the base that opens out to let the pouch stand. It is quoted as the full flat depth of that fold, and roughly half of it becomes the standing footprint.
When the pouch fills, height is lost as the gusset opens and the base spreads. That is why a filled pouch is shorter and fatter than the flat measurements suggest, and why shelf height should be checked against a filled sample rather than a spec sheet.
Why capacity is a density question
Two customers can order the same pouch and get very different fill weights, because volume is fixed and weight is not. Whole bean coffee, ground coffee, protein powder, granola, dried fruit and pet treats all pack differently into the same space. There is no honest conversion from pouch dimensions to ounces without knowing the product.
| To size a pouch, send us | Why it matters |
|---|---|
| The product itself, described plainly | Bulk density drives fill volume |
| Target fill weight per unit | Converts to a volume once density is known |
| How it will be filled, by hand or by machine | Machine filling constrains the format and the top seal |
| Shelf or display constraint, if any | Filled height, not flat height, is what has to fit |
Features to specify separately
Dimensions describe the shape. These describe how it behaves, and each is a separate line on a quote: a reclosable zipper, a one way degassing valve for freshly roasted coffee, a tear notch so the customer can open it without scissors, a hang hole for peg display, a rounded corner, and a clear window. Add only what the product needs. Every feature adds cost per unit and some of them constrain the sealing area, which can reduce usable capacity.
Print and artwork
Pouch artwork has to be built to the flat blank, then checked in the filled shape, because a design that reads correctly flat can end up with key elements wrapping into the gusset. Keep the brand mark and any legally required copy well inside the face panel, away from the seal edges and the base fold. The digital proof is the point to check this, and it comes before anything prints.
Ordering
iBox Factory's stated minimum is 100 boxes, and pouch formats are quoted per product, so confirm the minimum, the lead time and the film structure for your pouch on your written quote. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed in writing. Turnaround is stated per product across three lanes: rush is expedited production plus air freight, standard is air, and cost saver is sea. The floor is from about 7 business days plus 2 to 5 for delivery, and specialty imported items can run up to about 12 weeks. Rush adds about 7 to 25% depending on the job.
If you are packing coffee, the carton and sampler options are on custom coffee boxes. To size a pouch around your product, send the fill weight and product type through the quote form.
