Start with the product
The product determines the packaging structure. Coffee needs an oil and oxygen barrier, so PET/AL/PE or PET/NY/PE with a one-way degassing valve is common. Snacks need moisture and grease resistance. Tea needs aroma retention. Pet food needs puncture resistance and a strong seal. If you are unsure, request free stock pouch samples to test fit and feel before committing to a custom print run.
Consider the fill weight and the pouch format. Flat bottom pouches stand on the shelf and hold 250 g to 2 kg. Stand up pouches work for 100 g to 1 kg. Side gusset bags suit 500 g to 5 kg of coffee or pet food. Spout pouches, including corner spout and STANDCAP, are for liquids and semi-liquids. Rollstock film is for form-fill-seal lines.
Barrier is not one number
Barrier refers to how well a structure blocks oxygen, moisture, light and aroma. Aluminium foil (AL) gives the highest barrier. Metallised PET and EVOH are alternatives. Nylon (NY) adds toughness and pinhole resistance. PE is the seal layer. A three-layer structure such as PET/AL/PE covers most coffee and snack needs. For shorter shelf life, PET/PE or mono-material PE may be enough.
Light also matters. Clear windows show the product but let light in. If you need a window, place it away from the most light-sensitive area. For coffee, a one-way degassing valve releases CO2 while limiting oxygen ingress. Valves are added during pouch making, not after. Confirm the valve position with your supplier before printing.
Filling and sealing
The filling method affects the pouch design. Vertical form-fill-seal (VFFS) uses rollstock film. Pre-made pouches are filled on a separate line. For pre-made pouches, the zipper and tear notch must align with the fill opening. A tear notch above the zipper is common. For large bags, a carry handle or hang hole helps handling.
Seal contamination is a common cause of leakers. Powder, oil or crumbs in the seal area prevent a proper bond. If your product is dusty, consider a wider seal or a fold-over bottom. For liquids, a spout and cap allow clean filling and resealing. Always run a seal test at your target fill speed before full production.
Print methods and cost drivers
Print method drives cost and lead time. Digital printing suits short runs: from 100 pcs for pouches and 10 kg for film. Rotogravure suits larger runs: from 10,000 pcs or 200 kg. Rotogravure offers up to 10 colours and lower unit cost at volume, but adds cylinder costs and a longer lead time. Digital print runs ship in 10-15 working days after artwork approval. Rotogravure takes 20-25 working days.
Other cost drivers include material structure, pouch size, add-ons and print coverage. A one-way degassing valve, zipper, spout and cap, carry handle, hang hole, tear notch and window each add cost. Reducing the structure from three layers to two can lower cost if the barrier allows. Ask for a unit price, MOQ, lead time and shipping terms in writing before you approve artwork.
Sustainability rules
Recyclability depends on the full structure, not one layer. Mono-material PE and PP are designed for recycling streams where they exist. PLA/PBS compostable options need industrial composting. Degradable options exist but check the local rules. Kraft paper laminates give a natural look but usually include a plastic seal layer, so they are not automatically recyclable.
Keep the format simple. Fewer materials and fewer add-ons make recycling easier. If you add a valve or spout, check whether it can be removed. For coffee, a valve is often necessary. For dry snacks, a zipper may be enough. Always confirm claims with your supplier and test the packaging with your product before making public statements.
Common mistakes
Buyers often choose a pouch size before testing the fill weight. Order stock samples first. Another mistake is ignoring the fill line: too little headspace can cause seal contamination, too much wastes material. Not accounting for artwork bleed and print registration can delay production. Finally, do not assume a certification belongs to your supplier. Certifications belong to the manufacturing partner. Ask which factory will run your job and what it holds.
Plan for lead time. Digital print runs take 10-15 working days after artwork approval. Rotogravure takes 20-25 working days. Add shipping time. If you need stock samples, they are free; you pay courier only. Share your requirements, including product, fill weight, structure, print method and add-ons, to get a detailed offer with unit price, MOQ, lead time and shipping terms.