Custom Flat Bottom Pouches — Custom Size, Material, Thickness & Printing
A custom flat bottom pouch (also called a box pouch or quad seal pouch) is a self-standing flexible package built to your own dimensions, film structure, thickness and print design. Ruihong Packaging manufactures them in Foshan, China on 4 rotogravure lines — 7, 8, 9 and 11-color — plus digital printing, with MOQ 10,000 pcs gravure or 3,000 pcs digital per order.
- Custom size, structure, thickness and print
- Up to 11-color rotogravure printing
- 12-15 days gravure / 7-9 days digital production
Custom Flat Bottom Pouch: What You Can Specify
A custom flat bottom pouch is a flexible package manufactured to a buyer’s own dimensions, film structure, thickness, printing and accessories instead of being selected from a stock size list. On a flat bottom pouch you specify four things before production: bag width, height and bottom gusset; the material structure; the total thickness; and the printed design.
Custom size and gusset
Bag width 100-350 mm, height 150-450 mm, bottom panel 40-150 mm and side gusset depth built to the fill weight you actually pack.
Custom material structure
PET/PE, PET/VMPET/PE, PET/AL/PE or kraft paper laminations — chosen by barrier need, product type and target shelf life.
Custom thickness
90-180 µm total thickness. Light dry snacks usually run thinner; 1-5 kg pet food or coffee needs a heavier structure.
Custom printing and finish
Digital printing from 3,000 pcs per order, or rotogravure up to 11 colors, with matte, gloss or soft-touch finishes.
Comparing a custom build with a standard pouch? See the flat bottom pouches product page for ready structures, or read the custom packaging overview for other bag styles.
Custom Size and Gusset Options
Custom sizing on a flat bottom pouch is defined by four measurements: bag width, bag height, bottom panel width and side gusset depth. A deeper bottom panel and wider gusset increase the fill volume and the standing footprint; a shallower set keeps the pouch compact on a crowded shelf.
| Dimension | Custom range | How it changes your pouch |
|---|---|---|
| Bag width | 100-350 mm | Wider pouches stand more stably but need more shelf facing; also sets the film consumption per bag |
| Bag height | 150-450 mm | Drives fill volume and how much printed brand area you have for artwork |
| Bottom panel width | 40-150 mm | Wider panel = larger standing footprint and better stability for 1-5 kg fills |
| Side gusset depth | 30-120 mm | Deeper gusset adds volume without adding bag height |
| Fill weight reference | 100 g to 5 kg | Determines the structure and thickness we recommend for your size |
| Custom print design | With your own artwork | Print-ready files are supplied as AI or PDF with outlined fonts and die-lines |
Send a size in millimetres and the fill weight you pack. Our engineers confirm the bottom panel and gusset depth that hold your pouch upright at that weight, then quote both the size and the structure it needs.
Custom Material Structures and Thickness for Flat Bottom Pouches
Material structure and total thickness are the two variables that decide barrier performance, stiffness and cost. A custom flat bottom pouch usually runs 90-180 µm in total; the structure — not the thickness alone — controls how much oxygen and moisture reaches your product.
| Structure | Typical total thickness | Barrier level | Typical use |
|---|---|---|---|
| PET/PE | 90-110 µm | Standard | Dry snacks, candy, granola, hardware and parts |
| PET/VMPET/PE | 100-130 µm | Medium | Snacks, powder mixes, tea, dry pet treats |
| PET/AL/PE | 120-160 µm | High | Coffee, milk powder, protein powder, long shelf-life food |
| Kraft paper/VMPET/PE | 120-150 µm | Medium | Organic coffee, loose-leaf tea, natural-positioned brands |
| Heavy-duty PET/AL/PE | 160-180 µm | High | 2-5 kg pet food, bulk coffee, fertilizer and seed packs |
Lamination runs on 3 solvent-free lines and 2 dry lamination machines, so the same structure can be quoted in both technologies. Read more about our printing technology and material options on the browse by material page.
Custom Printing and Finishing Options
Custom printing on a flat bottom pouch runs two ways: digital printing from 3,000 pcs per order when the design changes often or volumes are small, and rotogravure printing from 10,000 pcs when the artwork is stable. Our gravure capacity reaches 11 colors, where most industry presses run 7-9.
| Option | What you can choose | Notes for your brief |
|---|---|---|
| Printing method | Digital or rotogravure | Digital: 3,000 pcs per order. Gravure: 10,000 pcs |
| Printing colors | Digital full color; rotogravure up to 11 colors | Gravure lines: 7, 8, 9 and 11-color presses |
| Surface finish | Matte, gloss, soft-touch, frosted, spot UV | Applied during lamination; registered matte-gloss is possible |
| Closure | Resealable zipper, press-to-close or slider style | Zipper is applied on the bag-making line |
| Valve | One-way degassing valve | Standard for freshly roasted coffee that releases CO₂ |
| Opening aids | Tear notch, laser score | Position confirmed on the artwork before printing |
| Retail features | Hang hole, euro slot, handle | Used for pegboard and club-store display |
| Window | Clear window or full transparent panel | Shows the product; slightly reduces barrier where the window sits |
Where Custom Flat Bottom Pouches Are Used
Custom flat bottom pouches are chosen where a brand needs a stable standing pouch with a large printable front panel and a heavier fill: roasted coffee, pet food and treats, milk and protein powder, loose-leaf tea, snacks, and personal care or home care products.
Coffee and tea
Coffee and tea brands customise the valve position, zipper and matte finish, and usually specify PET/AL/PE for freshness.
Coffee packaging solutions
Pet food and treats
1-5 kg fills use a 160-180 µm structure, a wider bottom panel and a reinforced bottom seal.
Pet food packaging solutions
Powder and nutrition
Milk powder, protein and nutritional blends specify PET/AL/PE with a wide bottom panel for scoop access.
Browse by material
Snacks and confectionery
Nuts, granola, biscuits and candy use PET/VMPET/PE with matte or registered matte-gloss finishes.
Custom snack packaging bags
Tea and herbal blends
Loose-leaf tea frequently uses kraft/VMPET/PE with a zipper and a clear window on the front panel.
Tea packaging solutions
Personal and home care
Bath salts, powders and refill products use soft-touch finishes with smaller bottom panels.
Custom packaging optionsQuad Seal, Box Pouch or Stand Up: Choosing the Right Structure
A quad seal flat bottom pouch has four vertical seals and a flat base; a box pouch (also written box bottom or K-seal) uses a folded bottom panel that forms a box shape. Both stand unaided. A stand-up pouch (doypack) also stands, but on a single folded bottom gusset rather than a full panel.
| Structure | Base design | Best for |
|---|---|---|
| Quad seal flat bottom pouch | Four vertical seals plus flat bottom panel | Rectangular shelf presence with a large front panel, 250 g to 2 kg |
| Box pouch / box bottom pouch | Folded bottom panel forming a box shape | Premium retail presentation and heavier fills up to 5 kg |
| Flat bottom pouch with zipper | Flat bottom plus resealable zipper | Coffee, tea and snacks that are opened and reclosed |
| Stand-up pouch (doypack) | Single folded bottom gusset | Lower unit cost where a flat base panel is not essential |
Need a resealable build? See flat bottom pouch with zipper. Need a kraft paper look? See kraft paper flat bottom pouches. For an aluminium foil structure, see aluminium foil flat bottom bags.
Custom Flat Bottom Pouch MOQ, Pricing and Lead Time
Custom flat bottom pouches start at MOQ 10,000 pcs for rotogravure printing or 3,000 pcs per order for digital printing. The lowest unit price is reached at one full roll of film, and production takes 12-15 days on gravure or 7-9 days on digital after artwork approval.
| Item | Value | What it means in practice |
|---|---|---|
| MOQ, gravure printing | 10,000 pcs | Printed from engraved cylinders; lowest unit cost at volume |
| MOQ, digital printing | 3,000 pcs per order | Digital printing itself has no minimum; the 3,000 pcs floor covers international shipping |
| Multi-SKU orders | SKUs can be combined | Several designs can be combined to reach 3,000 pcs, but unit price rises when a single SKU is very small |
| Best-price quantity | One full roll of film: 6,000 m | Quantity per roll = 6,000 ÷ bag width in metres |
| Production lead time, digital | 7-9 days | Counted from artwork approval and order confirmation |
| Production lead time, gravure | 12-15 days | Counted from artwork approval and order confirmation, not total transit time |
The one-roll rule: how buyers calculate the best price point
One roll of film holds 6,000 metres. The quantity that consumes one full roll is 6,000 ÷ bag width in metres, which is the same as 6,000,000 ÷ bag width in millimetres.
Example: for a 160 (W) × 240 (H) + 85 mm custom flat bottom pouch, one roll equals 6,000 ÷ 0.16 = 37,500 pcs.
What to Send for an Accurate Custom Quote
A custom flat bottom pouch price cannot be quoted from a photo alone. Five details decide the unit price: size in millimetres, material structure, total thickness, number of printing colors and order quantity. Quotes are normally returned within 24 working hours once these are known.
| Required detail | Example | Why we need it |
|---|---|---|
| Bag style | Flat bottom pouch with zipper and valve | Sets the bag-making line and accessory stations |
| Size | 160 (W) × 240 (H) + 85 mm bottom | Drives film consumption and the per-roll quantity |
| Fill weight | 500 g or 2 kg | Confirms thickness and seal design |
| Material structure | PET/AL/PE | Determines barrier level and cost |
| Thickness | 140 µm | Affects stiffness, protection and unit price |
| Printing | 8-color gravure, matte finish | Confirms the press and the cylinder requirement |
| Quantity and SKUs | 30,000 pcs, 2 designs | Decides whether gravure or digital is the better route |
| Delivery city | Hamburg, Germany | Lets us quote EXW, FOB or CIF terms |
Manufacturing Capability Behind Your Custom Order
Ruihong Packaging is a flexible packaging manufacturer in Foshan, Guangdong, China, founded in 2017. Printing, lamination, bag making and inspection run in house, so a change to your size, structure, thickness or print file is handled on our own lines instead of being subcontracted.
| Equipment | Quantity | What it does for your order |
|---|---|---|
| Rotogravure printing lines | 4 lines: 7, 8, 9 and 11-color | Colour-critical brand work; the 11-color press handles designs that 7-9 color presses cannot reach |
| Digital printing | In house | Short runs and multi-SKU orders from 3,000 pcs per order |
| Solvent-free lamination | 3 machines | Lamination without solvent residue, used for most food-contact structures |
| Dry lamination | 2 machines | Alternative lamination route for structures that need it |
| Bag making and auxiliary machines | 55 machines | Flat bottom, stand-up, three-side-seal and gusseted formats, with zipper application |
| Slitting machines | 4 machines | Roll preparation and film width control before bag making |
| Quality inspection machines | 6 machines | Every production batch is inspected before packing |
Custom Flat Bottom Pouch Process, Step by Step
The custom process runs in six steps: requirement and structure review, quotation with a die-line, artwork confirmation, printing, lamination and curing, then bag making and final inspection. Production time is counted from artwork approval and order confirmation, not from the first enquiry.
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STEP 01
Requirement and structure review
You send size, fill weight, product type and quantity. We confirm the structure, thickness and the accessory list for the pouch.
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STEP 02
Quotation and die-line
You receive a quotation with the printing option that fits your quantity, plus a die-line layout to place your artwork on.
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STEP 03
Artwork confirmation
Print-ready AI or PDF files are checked for outlined fonts, colour separation, zipper, valve and tear notch positions.
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STEP 04
Printing
Digital from 3,000 pcs per order, or rotogravure on 7, 8, 9 and 11-color presses from 10,000 pcs.
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STEP 05
Lamination and curing
Lamination runs on 3 solvent-free lines or 2 dry lamination machines, then the reel is cured for bond strength.
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STEP 06
Bag making and final inspection
Flat bottom forming with zipper and valve stations, then seal and appearance checks on 6 inspection machines before export packing.
Related pages: custom packaging process · sample policy · quality control system
Quality Control on Custom Flat Bottom Pouch Orders
Because every custom order is a new size, structure, thickness and print file, quality control starts before printing rather than at the end of the line. Incoming film, printed colour, lamination bond and finished seals are each checked, and 6 inspection machines run through every batch.
- Incoming material check — film and laminates verified against the structure and thickness on your order.
- Print verification — colours and registration checked against the approved proof before the run continues.
- Lamination check — bond strength and curing confirmed on the solvent-free or dry lamination line.
- Bag-making dimensions — width, height, bottom panel and gusset depth measured against the approved die-line.
- Seal and zipper check — bottom seal integrity, zipper function and valve seating checked on samples per batch.
- Final inspection and packing — appearance checked on 6 inspection machines, then export cartons are packed and marked.
Custom Flat Bottom Pouches: Buyer Questions
These are the questions buyers ask most often when sourcing custom flat bottom pouches, with the figures our quotations are based on. If your case is different, send the specification and we will answer against your size, structure and quantity.
Gravure printing starts at 10,000 pcs and digital printing at 3,000 pcs per order. Digital itself has no minimum; the 3,000 pcs floor covers international shipping. Several SKUs can be combined to reach it, but unit price rises noticeably when a single SKU is very small.
Yes. One order can combine a custom size (100-350 mm wide, 150-450 mm high, 40-150 mm bottom panel), a chosen structure such as PET/AL/PE, a total thickness of 90-180 µm and up to 11-color rotogravure printing. All four are confirmed on a single die-line before production.
It depends on the product. PET/PE at 90-110 µm suits dry snacks; PET/VMPET/PE at 100-130 µm adds medium barrier for tea and powder mixes; PET/AL/PE at 120-160 µm is used for coffee, milk powder and long shelf life; 2-5 kg pet food usually needs 160-180 µm.
Unit price depends on bag width, height, structure, thickness, number of print colors and quantity, so it is quoted per specification rather than from a list. The best price point is one full roll of film, 6,000 m — for a 160 (W) × 240 (H) + 85 mm pouch that is 37,500 pcs.
Production takes 7-9 days for digital printing and 12-15 days for gravure printing, counted from artwork approval and order confirmation. That is production time only and does not include sampling or international transit, which are quoted separately.
Yes. Flat bottom pouches are commonly built with a resealable zipper, a one-way degassing valve for roasted coffee, a tear notch, a hang hole or euro slot, a handle, and a clear or full transparent window. Positions are confirmed on the die-line before printing.
Send a print-ready AI or PDF file with fonts outlined, plus any brand colour references. We provide the die-line for your confirmed size so artwork can be placed correctly for the zipper, valve, tear notch and bottom panel. We check colour separation before printing.
Yes. Stock samples without your print are free, with freight collected on your courier account. Custom digital samples made to your size, structure and design are charged per specification because they use a production run. Full details are on our sample policy page.
Request a Custom Flat Bottom Pouch Quote in 24 Hours
Send these details and Jason will reply with a unit price, a structure recommendation and the printing route that fits your quantity.
- Bag style, size in mm and target fill weight
- Material structure and total thickness
- Printing method, number of colors and finish
- Accessories: zipper, valve, hang hole, window
- Order quantity, including how many SKUs
- Delivery city, so we can quote EXW, FOB or CIF
Flexible packaging manufacturer in Foshan, Guangdong, China — since 2017
Jason · Jason@ruihongpackaging.com · +86 189 2597 5915
Ready to Build Your Custom Flat Bottom Pouch?
Send your size, structure, thickness and artwork. We will confirm the die-line, the printing route and the unit price for your quantity.
Last updated: 2026-10-03