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Packaging Pouch Size Chart | GT Pack Industries India ' + '
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Dimensions in mm (external, flat before filling)  Â·  Tolerance ±2mm  Â·  Calibrated to ~0.5 g/cc bulk density

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GT Pack Industriesgtpackexim.com
+91 9810769613
gtpacks@gmail.com
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' + 'GT Pack Industries  Â·  Plot No. B-100, Ecotech VI, Kasna, Greater Noida  Â·  ISO 9001 | 22000 | 14001 | 45001' + 'Custom sizes available  Â·  WhatsApp: +91 9810769613' + '
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Flexible Packaging Pouches · Size Guide · B2B Reference

The wrong pouch size kills your shelf appeal, wastes material, and breaks your packaging line. Flexible Packaging Pouch Size Chart — Stand-Up, Center Seal, Side Seal & Gusset, 50g to 10kg.

Every flexible packaging buyer has been there: a pouch that's too big looks unprofessional on shelf; one that's too small splits at the seal; the gusset depth is wrong and the bag won't stand. This guide gives you industry-standard sizes for the four pouch formats GT Pack manufactures in-house — stand-up, center seal, side seal, and gusset — across all FMCG weight ranges from 50g to 10kg. Use it to specify your packaging with confidence.

4Core Pouch Formats
9Standard Weight Ranges
±2mmProduction Tolerance
ISO 900122000 · 14001 · 45001
The Cost of Wrong Sizing

What happens when pouch dimensions don't match your product

Most packaging failures don't happen at the laminate. They happen at the dimensions — buyers who specify pouches by gut feel or by copying a competitor's pouch end up with three avoidable costs that compound across every production run.

PROBLEM 01

Material Waste

An oversized pouch uses 8–15% more laminate per unit than a properly-sized one. Over a 100,000-pouch run, that's lakhs in extra material cost — paid by you, on every batch, for every product.

PROBLEM 02

Line Stoppages

Pouches that don't match the FFS machine's dimensional tolerance jam the seal jaws, misalign at the cutter, and force operators to slow throughput. A 10% loss in line speed wipes out months of margin.

PROBLEM 03

Lost Shelf Presence

A pouch that won't stand straight, looks half-empty, or sags at the gusset gets passed over by retail buyers in three seconds. Wrong dimensions cost you the shelf — and there's no fixing that with better artwork.

Four Core Formats

The packaging pouches GT Pack manufactures in-house

These four formats cover roughly 90% of FMCG, food, and pharma packaging demand in India and across export markets. Each has a structural logic — and a specific cost, capacity, and shelf-presence profile.

FORMAT 01

Stand-Up Pouch

The shelf-presence champion

Doypack format with a bottom gusset that opens up when filled, allowing the pouch to stand upright on shelf. The most-specified retail pouch globally — strong shelf appeal, premium feel, accommodates zippers, spouts, valves, and tear notches.

  • Dry fruits, nuts, namkeen
  • Tea, coffee (with valve)
  • Spices, masala, instant mixes
  • Pet food, treats
💬 Enquire on WhatsApp
FORMAT 02

Center Seal Pouch

The cost-efficient workhorse

Pillow pack with a single back seal running vertically — minimum material, maximum production speed. The default format for FFS lines, sachets, and single-serve. Doesn't stand up, but the lowest cost-per-pouch of any format we make.

  • Single-serve sachets, sample packs
  • Candy, confectionery, biscuits
  • Spice and powder sachets
  • Snack packs, salt, sugar sachets
💬 Enquire on WhatsApp
FORMAT 03

Side Seal Pouch

The premium clean-edge format

Three-side seal flat pouch — sealed on left, right, and bottom — giving a clean, square-edge appearance preferred for premium products and pharma. More material than center seal, but a cleaner aesthetic and a stronger seal profile.

  • Premium spices, masala blends
  • Cosmetic samples, single-dose pharma
  • Specialty teas, supplements
  • High-end snacks, premium powders
💬 Enquire on WhatsApp
FORMAT 04

Gusset Pouch

The heavy-load specialist

K-Seal block-bottom or side-gusset pouch built for high-weight, high-volume products. Distributes load across a flat base, packs efficiently into shipping cartons, and supports degassing valves and tin ties. Scales up to 20kg in custom runs.

  • Coffee beans (with valve)
  • Rice, grains, pulses
  • Pet food (large format)
  • Protein powder, industrial powders
💬 Enquire on WhatsApp
Complete Size Tables

Industry-standard pouch dimensions for every weight range

Dimensions in millimeters, external. Format: Width × Height × Gusset. Calibrated to average FMCG bulk density (~0.5 g/cc). For light products (puffed snacks) size up one tier; for dense products (sugar, salt) size down one tier. Tolerance ±2mm.

Stand-Up Pouch — Size Chart

Format 01 · Bottom Gusset
Product WeightWidth (mm)Height (mm)Gusset (mm)Typical Application
50 g10015040Single-serve spices, sample sachets, instant mixes
100 g12018050Saffron, cardamom, specialty tea, premium spices
200 g14022060Tea, instant coffee, dry fruits, baking ingredients
250 g15023070Coffee, premium nuts, specialty snacks
500 g16527090Coffee beans, dry fruits, snacks, namkeen, cereals
1 kg200300100Bulk dry fruits, namkeen, atta samples, pet food
2 kg230360110Bulk grains, large pet food, industrial powders
5 kg280400120Heavy dry goods, industrial chemicals, bulk feed
10 kg320450140Industrial bulk packaging, heavy feed, granules
Add-ons available: Zipper, tear notch, hang hole, euro slot, degassing valve, spout fitment. 💬 Know More

Center Seal Pouch — Size Chart

Format 02 · No Gusset
Product WeightWidth (mm)Height (mm)Typical Application
50 g80120Sachet, single-serve sugar, salt, sample pouches
100 g100150Spices, powders, candy, confectionery
200 g120180Tea, snacks, smaller portions
250 g130200Snack packs, namkeen, biscuits
500 g140220Snacks, sugar, salt, namkeen retail packs
1 kg160260Atta, sugar, rice (retail), pulses
2 kg180300Bulk pulses, sugar, retail grain packs
5 kg220360Bulk retail rice, atta, industrial use
10 kg260420Bulk industrial powders, granules, grains
Add-ons available: Tear notch, hang hole, euro slot. Optimised for FFS lines. 💬 Know More

Side Seal Pouch — Size Chart

Format 03 · 3-Side Seal
Product WeightWidth (mm)Height (mm)Typical Application
50 g85130Premium sachets, cosmetic samples, single-dose pharma
100 g110170Premium spices, specialty teas, supplements
200 g130210Specialty foods, masala blends, premium powders
250 g140220Premium coffee, cocoa, specialty grain
500 g160250Premium snacks, dry fruits, specialty packaging
1 kg180300Bulk specialty grains, premium powders
2 kg210340Bulk premium packaging, industrial pharma
5 kg250390Heavy specialty bulk, industrial premium
10 kg290440Industrial bulk, heavy pharma, premium feed
Add-ons available: Zipper, tear notch, hang hole, euro slot. Best premium aesthetic. 💬 Know More

Gusset Pouch — Size Chart

Format 04 · K-Seal Bottom
Product WeightWidth (mm)Height (mm)Gusset (mm)Typical Application
50 g9513045Premium coffee samples, specialty tea
100 g12017060Coffee beans, specialty spices, premium pet treats
200 g14021075Coffee, premium powders, gourmet items
250 g15024080Coffee beans, gourmet rice, specialty nuts
500 g16527090Coffee, pet food, premium snacks, granola
1 kg190310110Bulk coffee, premium grains, pet food
2 kg220360120Heavy bulk premium, large pet food, protein powder
5 kg270410140Industrial heavy goods, bulk pet food, fishing bait
10 kg320470160Industrial heavy-duty, bulk powders, granules
Add-ons available: Degassing valve, tin tie, reseal sticker. Zippers limited due to gusset folds. 💬 Know More
Side-by-Side Comparison

Quick reference: all four formats, side by side

Compare dimensions across all formats for the same product weight — useful when deciding between, say, a side-seal vs. stand-up for a 500g product. Dimensions in mm.

Weight Stand-Up
(W × H × G)		 Center Seal
(W × H)		 Side Seal
(W × H)		 Gusset
(W × H × G)		 Best Format For
50 g100×150×4080×12085×13095×130×45Center Seal (cost) · Side Seal (premium)
100 g120×180×50100×150110×170120×170×60Stand-Up (retail) · Side Seal (premium)
200 g140×220×60120×180130×210140×210×75Stand-Up (retail)
250 g150×230×70130×200140×220150×240×80Stand-Up · Gusset (coffee)
500 g165×270×90140×220160×250165×270×90Stand-Up · Gusset (coffee, pet food)
1 kg200×300×100160×260180×300190×310×110Gusset (bulk) · Stand-Up (retail)
2 kg230×360×110180×300210×340220×360×120Gusset (heavy load)
5 kg280×400×120220×360250×390270×410×140Gusset (industrial)
10 kg320×450×140260×420290×440320×470×160Gusset (industrial heavy-duty)
End-Use Applications

Which industries use packaging pouches from GT Pack?

GT Pack's four core pouch formats serve manufacturers across food, FMCG, pharma, agro, and industrial sectors — in India and across export markets including UAE, Saudi Arabia, UK, Germany, Nepal, and Sri Lanka.

Food & FMCG

Spices, masala, namkeen, snacks, dry fruits, atta, salt, sugar, tea, coffee, instant mixes, confectionery, biscuits, cereals, breakfast products.

Pharmaceuticals

Single-dose sachets, bulk powder pharma, nutraceuticals, dietary supplements, hospital-grade laminate pouches, EO sterilizable formats.

Pet Food & Treats

Dog and cat food (kibble), pet treats, fish food, bird food, equine supplements — gusset pouches with degassing valves for large packs.

Agro & Seeds

Seed packaging, fertilizer sachets, pesticide pouches, granular agrochemicals, organic farming inputs — barrier-grade laminate options.

Personal Care & Cosmetics

Shampoo and conditioner sachets, cream and lotion samples, hair color sachets, face mask packaging, premium cosmetic single-use formats.

Industrial & Chemicals

Industrial powders, granules, mineral powders, construction admixtures, bulk chemical packaging up to 25kg in customized gusset formats.

Why G T Pack

Manufacturing infrastructure that backs the spec sheet

Every dimension on this page is delivered out of G T Pack's facility in Greater Noida — Plot No. B-100, Ecotech VI, Kasna — with 8-colour rotogravure printing, solvent lamination, extrusion coating, slitting, and pouch-making under one roof. Production capacity 250 tonnes per month. 70-member workforce. 10% year-on-year growth — roughly double the industry average.

We export to UAE, Saudi Arabia, UK, Germany, Nepal, and Sri Lanka. Custom sizes, custom laminate structures, and full barrier specification (WVTR, OTR data on request) are standard offerings — not premium upsells.

  • ISO 9001 · Quality Management

    Documented quality system across printing, lamination, and pouch-making. Every batch traceable.

  • ISO 22000 · Food Safety

    Food-contact certified laminate manufacturing. Direct compliance with FMCG and food-grade requirements.

  • ISO 14001 · Environmental Management

    Systematic environmental controls — solvent recovery, waste minimisation, compliance with India and EU norms.

  • ISO 45001 · Occupational Health & Safety

    Workforce safety standards across the 1,200 sq m facility. Audited annually.

FAQ Section

Flexible Packaging Pouches — Frequently Asked Questions

Real questions packaging buyers ask when sizing and specifying pouches — covering dimensions, format selection, weight ranges, add-ons, and laminate structures.

What size pouch do I need for 500g of product?

For an average-density food product weighing 500g, the industry-standard stand-up pouch is 165mm × 270mm × 90mm bottom gusset. Complete 500g sizing across GT Pack's four formats:

Stand-Up: 165 × 270 × 90mm  Â·  Center Seal: 140 × 220mm  Â·  Side Seal: 160 × 250mm  Â·  Gusset: 165 × 270 × 90mm.

For unusually light products like puffed snacks, size up one tier. For dense products like sugar or salt, you can size down slightly without losing fill quality.

What is the difference between center seal and side seal pouches?

A center seal pouch has a single vertical back seal running down the back of the pouch — pillow pack format. It uses the least material per unit and is the most cost-efficient format. Best for FFS lines, single-serve sachets, and cost-sensitive products.

A side seal pouch (3-side seal) is sealed on three edges — left, right, and bottom — giving a clean, square-edge appearance preferred for premium products, pharma, and cosmetics. Slightly more material, but a stronger seal profile and a more premium feel on shelf.

Which pouch type is best for heavy products like 5kg or 10kg?

Gusset pouches with a K-Seal block-bottom construction are the best fit for heavy products from 5kg to 20kg. They distribute load across a flat base, sit stably on shipping pallets, and resist puncture failure better than stand-up doypack formats.

Stand-up pouches are also viable up to 10kg, but require thicker laminate structures (typically PET 12µ / MET PET 12µ / PE 100+µ) and reinforced bottom gussets.

Can I get custom-sized packaging pouches from GT Pack?

Yes. GT Pack Industries manufactures custom-sized pouches across all four core formats. Standard production tolerance is ±2mm. Minimum order quantity is typically 25,000 pouches per SKU, with lower MOQs available on consultation.

Contact GT Pack with your product's bulk density, target weight, and packaging line specs — we'll recommend the right format, laminate structure, and dimensions before committing to a print run.

What is the standard size for a 1kg stand-up pouch?

The industry-standard size for a 1kg stand-up pouch is 200mm width × 300mm height × 100mm bottom gusset. This is calibrated for average food bulk density (~0.5 g/cc) — atta, namkeen, dry fruits, pet food, and similar products.

For lighter products like puffed snacks, sizing may need to scale up to 230 × 320 × 110mm. For dense products like sugar or rice, 180 × 280 × 90mm also works well.

What is the gusset on a stand-up pouch and why does it matter?

The gusset is the folded panel at the bottom of a stand-up pouch that opens out when the pouch is filled, creating the flat base that lets it stand upright. Gusset depth is measured as the total width of the opened panel.

A deeper gusset gives more product capacity and better shelf stability — but it also requires more material per pouch. Industry-standard ratio: gusset depth is roughly 30–40% of the pouch width.

How do I measure a packaging pouch correctly?

All pouch dimensions on this page are external dimensions, measured flat before filling. Convention: Width × Height × Gusset, in millimeters.

Width: edge to edge across the front face. Height: from top edge to bottom edge. Gusset: open the bottom flat and measure depth front-to-back. Note: actual fillable area is smaller than external dimensions because of seal zones at edges (typically 8–12mm per side). Production tolerance at GT Pack is ±2mm.

What laminate structures does GT Pack offer for these pouches?

GT Pack manufactures pouches across all major laminate families: PET / MET PET / PE (general FMCG), BOPP / MET BOPP / PE (snacks and namkeen), PET / ALU / PE (high-barrier for spices, coffee, pharma), Paper-based laminates (eco-friendly options), and Retort-grade structures for heat-processed foods.

Full barrier data (WVTR and OTR) is available on request for every laminate structure. We'll recommend the right structure based on your product's moisture sensitivity, oxygen sensitivity, and target shelf life.

Specify Your Packaging

Found the size you need? Now let's spec the right laminate.

Sizing is the starting point. The right laminate structure — barrier grade, micron specs, surface finish — is what protects your product through shelf life. Send us your product details and target market, and we'll come back with a complete spec including dimensions, laminate, and price per pouch.

Request a Quote → 💬 WhatsApp Us
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FACILITY · Plot No. B-100, Ecotech VI, Kasna, Greater Noida CAPACITY · 250 Tonnes / Month EXPORT · UAE · KSA · UK · Germany · Nepal · Sri Lanka