Pouch sizing guide
Recommended starting dimensions for our most requested formats across coffee, alcohol & beverages, automotive, health & beauty and supplements. Every product fills differently, so treat these as a starting point and fill-test with your actual product before finalising.
Whole roasted beans need enough room for their relatively bulky shape. For freshly roasted coffee, allow for a one-way degassing valve where required.
| Net weight | W × H × BG (mm) |
|---|---|
| 100 g | 120 × 190 × 50 |
| 250 g | 150 × 230 × 80 |
| 350 g | 160 × 250 × 80 |
| 500 g | 180 × 265 × 100 |
| 1 kg | 230 × 320 × 110 |
| Net weight | W × H × BG (mm) |
|---|---|
| 100 g | 100 × 160 × 60 |
| 250 g | 120 × 200 × 80 |
| 350 g | 125 × 220 × 80 |
| 500 g | 140 × 265 × 85 |
| 1 kg | 150 × 340 × 100 |
These are consistent with common references for 250 g, 500 g and 1 kg coffee bags, including stock flat bottom bags of around 120 × 200 mm for 250 g and 145–150 × 320–340 mm for 1 kg.
Based on instant coffee granules, rather than whole beans or ground coffee. Granule size and bulk density vary by production method, so these are conservative starting sizes rather than assuming all granules pack densely.
| Net weight | W × H × BG (mm) |
|---|---|
| 100 g | 120 × 190 × 50 |
| 250 g | 150 × 230 × 80 |
| 350 g | 160 × 250 × 80 |
| 500 g | 180 × 265 × 100 |
| 1 kg | 230 × 320 × 110 |
| Net weight | W × H × BG (mm) |
|---|---|
| 100 g | 100 × 160 × 60 |
| 250 g | 120 × 200 × 80 |
| 350 g | 125 × 220 × 80 |
| 500 g | 140 × 265 × 85 |
| 1 kg | 150 × 340 × 100 |
Sizing note: freeze-dried or larger, irregular granules may need more space than finer spray-dried granules. Use the actual granules for a fill test before finalising the pouch.
Ground coffee can pack more densely than whole beans, but grind size, roast and aeration affect the final volume. These sizes offer a slightly more compact option for the smaller weights while keeping practical headroom for filling and sealing.
| Net weight | W × H × BG (mm) |
|---|---|
| 100 g | 100 × 160 × 50 |
| 250 g | 130 × 210 × 70 |
| 350 g | 140 × 230 × 80 |
| 500 g | 160 × 250 × 90 |
| 1 kg | 200 × 300 × 100 |
| Net weight | W × H × BG (mm) |
|---|---|
| 100 g | 90 × 150 × 55 |
| 250 g | 110 × 190 × 75 |
| 350 g | 120 × 220 × 80 |
| 500 g | 125 × 260 × 85 |
| 1 kg | 140 × 320 × 100 |
The smaller sizes are provisional recommendations, not a claim that ground coffee always fits a smaller pouch than beans. If you are packing very fine, aerated or freshly ground coffee, test the larger bean-pouch size as well.
For liquids, capacity is measured in millilitres or litres rather than grams. These dimensions assume a conventional flexible stand-up spout pouch for a relatively free-flowing liquid, such as a drink, juice, syrup, liquid supplement, lotion or automotive fluid.
| Fill volume | W × H + BG (mm) |
|---|---|
| 100 ml | 90 × 130 + 50 |
| 250 ml | 120 × 170 + 50 |
| 500 ml | 140 × 200 + 60 |
| 750 ml | 160 × 230 + 80 |
| 1 litre | 165 × 255 + 90 |
| 1.5 litres | 200 × 280 + 120 |
| 2 litres | 220 × 310 + 120 |
| 2.5 litres | 240 × 340 + 130 |
The 100 ml–1.5 litre sizes follow published spout pouch sizing guidance. The 2 litre and 2.5 litre sizes are extrapolated starting recommendations and need particular care with the base, spout placement and filled-pouch stability, so we always test them filled with the actual liquid before production.
Based on a typical dry supplement or protein powder. These sizes allow for a zipper and practical filling headspace. Very fluffy blends may need the next size up, while dense mineral powders may fit a smaller format.
| Net weight | W × H × BG (mm) |
|---|---|
| 250 g | 150 × 230 × 70 |
| 500 g | 180 × 260 × 90 |
| 1 kg | 200 × 320 × 100 |
| 2 kg | 230 × 360 × 110 |
| 2.5 kg | 265 × 420 × 130 |
| Net weight | W × H × BG (mm) |
|---|---|
| 250 g | 120 × 220 × 80 |
| 500 g | 140 × 250 × 90 |
| 1 kg | 160 × 300 × 100 |
| 2 kg | 200 × 380 × 120 |
| 2.5 kg | 220 × 410 × 130 |
The 250 g–1 kg sizes are based on common pouch proportions for powders and protein products; the larger formats are indicative extensions of those proportions. 1 kg powder packs are commonly around 200 × 300–320 mm with a 90–100 mm gusset.
For 2 kg and 2.5 kg products, pay particular attention to film strength, bottom-seal width and the zipper’s ability to withstand repeated use. A heavier fill may need a thicker laminate even if the dimensions are sufficient.
Based on pouches filled with finished capsules, including their shells, rather than loose powder. Capsule sizes 00, 0 and 1 differ in volume: nominal capacities are roughly 0.95 ml for size 00, 0.67 ml for size 0 and 0.50 ml for size 1, although exact specifications vary by manufacturer. How many capsules make up a given weight also depends on the formulation and fill density.
| Net weight of capsules | W × H × BG (mm) |
|---|---|
| 100 g | 100 × 160 × 50 |
| 150 g | 120 × 190 × 50 |
| 250 g | 140 × 220 × 70 |
| 350 g | 150 × 240 × 80 |
| 500 g | 170 × 270 × 90 |
| Net weight of capsules | W × H × BG (mm) |
|---|---|
| 100 g | 100 × 160 × 50 |
| 150 g | 120 × 190 × 50 |
| 250 g | 140 × 230 × 70 |
| 350 g | 160 × 250 × 80 |
| 500 g | 180 × 280 × 90 |
| Net weight of capsules | W × H × BG (mm) |
|---|---|
| 100 g | 110 × 170 × 50 |
| 150 g | 120 × 200 × 60 |
| 250 g | 150 × 230 × 80 |
| 350 g | 170 × 260 × 90 |
| 500 g | 190 × 290 × 100 |
Important: these capsule dimensions are preliminary sizing recommendations. The size 1 sizes allow extra room for the greater number of smaller capsules needed to reach the same net weight. Run a volume and fit test with your actual capsules before ordering printed pouches.
| Product | Recommended starting format |
|---|---|
| Coffee beans, 100–500 g | SUP or flat bottom with zipper |
| Coffee beans, 1 kg | Flat bottom with degassing valve |
| Instant coffee granules | SUP or flat bottom with high-barrier film |
| Ground coffee | SUP or flat bottom; consider aroma and moisture barrier |
| Liquid, 100–500 ml | Corner- or top-spout pouch |
| Liquid, 750 ml–1 litre | Larger stand-up spout pouch |
| Liquid, 1.5–2.5 litres | Reinforced, tested spout pouch |
| Supplement powder, 250 g–1 kg | SUP or flat bottom with zipper |
| Supplement powder, 2–2.5 kg | Reinforced flat bottom or quad seal |
| Supplement capsules | SUP with zipper; size according to capsule dimensions and net weight |
For coffee, choose a suitable oxygen-barrier laminate and a degassing valve if required. For supplements, choose the barrier structure based on the powder or capsule’s sensitivity to moisture, oxygen and light. Material construction, seal design and closure requirements are specified separately from pouch dimensions.
If none of these standard sizes fit your product, we can make your pouch to any dimensions. Give us a call or request a quote and we will help you find the right size.
