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How to Size a Flat Pouch: Turn Fill Weight into Finished Width and Length (Video)

This 60-second video sums up the buying guide. The full article covers the details and sources.

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Video transcript

  1. 0:00Most flat-pouch sizing errors start with a size picked by eye.
  2. 0:05Pouches hold volume, not grams. Weigh a known volume as it reaches the filler: same weight, different density, different space. Powders settle in transit.
  3. 0:16Width comes from filling: clear the nozzle and leave room to open the mouth. Filled, the pouch puffs into a pillow, so fill well below its maximum.
  4. 0:27Build from the inside out: cavity first, seal bands on every edge, headspace for clean seals, the notch above the fill, a header only for hanging.
  5. 0:38Before printing, trial plain pouches at your size and a step either side. Check: product below the notch, clean seals, carton fit, acceptable slack after a shake.
  6. 0:50Bring outside and inside sizes, plus your assumed seal width.
  7. 0:55Add quantity and artwork for a quote.

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