Custom Flat Pouches

When a Flat Pouch Is the Right Choice

A flat pouch wins wherever a pack does not need to stand. That sounds like a narrow case and it is not: a large share of retail food is merchandised on a pegboard, in a shallow tray, in a counter display, or inside an outer case that does the standing instead.

The construction is front and back panels sealed along three edges. There is no gusset to open and no base to fill, which removes two things at once: the film the other formats spend on structure, and the requirement that the pack be filled enough to hold its shape. A flat pouch holds its form whether it is full or half full.

That makes the format forgiving where fill weight varies. A product sold in approximate weights, or one that settles in transit, presents badly in a stand-up pouch that suddenly slumps. A flat pouch does not care.

Single-Use or Resealable

A flat pouch is often the format for a single-use portion, and the closure follows from that. A tear notch gives a clean opening without scissors and costs very little, which suits a pack that is opened once and finished.

A resealable zipper is available on this format where the pack holds multiple servings, and a hang hole suits pegboard or clip-strip display. Which of these a pack needs is a question about how the customer uses it rather than a property of the construction.

Fill weight, again, comes from the product. The table maps a selling situation to a format, and every figure is confirmed against what you actually pack.

Custom and Other Configurations

Construction, seal type, dimension, closure and finish are all made to a specification, so a configuration that is not listed is generally a question of confirming it against a manufacturer rather than whether it exists.

Features

The flat format accepts a narrower feature set than gusseted pouches (there is no base to fit a zipper into) but the features it does take are the ones that matter most in flat retail.

Free Digital Mockup and Optional Physical Sample

Before anything is manufactured, you receive a free digital mockup showing your artwork on the pouch you have specified at the size, the barrier structure, the fitted features, the finish and the print coverage you chose. There is no charge for it and no production order is required to receive it. For a flat pouch the mockup is doing a particular job: it shows how your artwork reads against a fully printed panel, against a clear film with a printed back, or against a kraft panel with a window, and those are three different visual decisions that look the same on a design file but do not on the finished pack.

It is also where the format's specific behaviour shows up. A flat pouch lies rather than stands, hangs rather than sits on a shelf, and is often merchandised inside a tray, on a peg, or inside an outer case rather than on its own, which means the mockup is what tells you whether the design reads as well at the size the customer will see it in the actual retail context. An optional custom physical sample can be produced after artwork approval, and the sample fee is credited back toward your production order if you proceed.

• The mockup is the artwork on the pouch, at the size, finish and print coverage you chose.
• The mockup is free and no production order is needed to receive it.
• If you proceed, the mockup is the artwork we run.
• A physical sample confirms how the pouch lies, hangs and presents in the merchandising it will sit in.
• The sample cost is credited toward the production order if you go ahead.

Artwork Requirements

Supply vector artwork for the cleanest print result, particularly if the same design will print across a range of pouch sizes.

• Preferred: AI, EPS, SVG, or PDF, vector formats.
• Acceptable: PNG or JPG at high resolution.
• If you only have your logo, we can prepare the pouch layout for you.
• A color reference (hex code, Pantone number, or a physical sample) helps us match accurately.

Production & Delivery

These pouches are custom manufactured after you approve the design and pricing. They are not pulled from stock. The sequence is: configure your specifications, receive a free digital mockup, approve the design and pricing, manufacturing begins, then the completed order is delivered nationwide.