Custom Flat Bottom Pouches
Five panels instead of three changes what a pouch can do. A flat bottom pouch has a base, two sides, a front and a back, and stands square rather than leaning. Coffee roasters moved over almost entirely. We produce a lot of flat bottom pouch work at ZEE Packaging and shelf presence drives it.
It Stands Like A Box
A flat bottom pouch keeps its shape on a shelf.
- The base is a real panel rather than a fold
- A flat bottom pouch stands square, not leaning
- Two side gussets give extra printable faces
- More product fits the same footprint
- A flat bottom pouch reads closer to a carton
- It stays upright when half emptied
Most brands move to a flat bottom pouch because stand up kept toppling.
Five Panels To Design Across
The extra faces change your artwork approach.
- The front carries main branding
- The back holds ingredients and legal copy
- Both gussets on a flat bottom pouch print too
- The base can carry batch coding
- Artwork can wrap around all sides
- Most brands leave the gussets blank, which wastes them
- Standard flat bottom pouch our everyday build
- Zippered flat bottom pouch for multi use products
- With a degassing valve for fresh roasted coffee
- Window flat bottom pouch product visible behind film
- With a tin tie a traditional coffee closure
- Tear notch opening without scissors
Sizes We Print Regular
Every flat bottom pouch is built to your fill, though these run often:
- 250g for coffee in a flat bottom pouch
- 500g for a larger coffee format
- 1kg for bulk coffee and protein powder
- 100g for samples and small fills
- 2kg for pet food and dry bulk
- Custom volumes for your product
Fill and settle a sample first. Powders compact, and a flat bottom pouch sized on loose volume looks empty.
Film And Barrier
- PET outer for print quality and strength
- Foil or metallised for the oxygen barrier
- Polyethylene inner for a reliable heat seal
- Kraft outer on a flat bottom pouch for a natural look
- Mono material PE for better recyclability
- Food grade certified film throughout
Barrier follows shelf life. Tell us how long it must last and we specify the structure rather than guess.
Honest Notes On Recycling
- A mono material flat bottom pouch recycles in normal streams
- Foil laminates give the best barrier, worst recycling
- A compostable flat bottom pouch suits some products
- Paper based laminates are improving steadily
- Soy based ink through the whole run
- Right sizing so less film gets used
There is a real trade off and we would rather name it. Mono material has improved, though it trails foil on oxygen.
How An Order Runs With Us
- 100 unit minimum, so a small roaster can launch
- Free 3D mockup and proof before printing
- Free artwork setup by our designer
- Physical sample, filled and sealed on request
- Urgent turnaround at 5 to 8 business days
- Free worldwide shipping included
Frequently Asked Questions
Why a flat bottom pouch over stand up?
It stands squarer, holds more in the same footprint and adds two printed faces.
How much do flat bottom pouches cost?
Rough estimate is $0.12 to $0.30 on a simple structure, $0.20 to $0.45 with foil barrier and $0.28 to $0.60 with valve and zipper at moderate volume. Shipping is included. This is estimate only, so ask us for a exact quote.
Do we need a degassing valve?
For fresh roasted coffee, yes. Without one a flat bottom pouch swells and splits.
Can a flat bottom pouch be resealed?
With a zipper or tin tie. Both suit a flat bottom pouch used over weeks.
Is a mono material version available?
It is, and a mono flat bottom pouch recycles far better. Barrier trails foil slightly.
Can you print the side gussets?
Yes, and we push for it. Blank gussets waste two of five panels.
Digital or rotogravure?
Digital for short runs and several SKUs. Rotogravure once volume absorbs the plate cost.
