Custom Lay Flat Pouches
Not everything needs to stand upright. Sachets, samples, powders and anything posted through a letterbox are better flat. A lay flat pouch has no gusset and no base, just two sealed faces. We produce a lot of lay flat pouch work at ZEE Packaging and simplicity is why it costs less.
Flat Is Cheaper And Lighter
A lay flat pouch strips out everything that is not needed.
- No gusset or base means less film per unit
- A lay flat pouch weighs less than a stand up
- It posts flat, keeping you in a cheaper band
- Storage takes almost nothing before filling
- A simpler structure costs less per unit
- Filling lines run it faster than a gusseted format
Most brands choosing a lay flat pouch ship direct and watch postage.
Where Flat Beats Standing
The format suits particular products well.
- Single serve sachets and sample sizes
- Supplements and powders in a fixed dose
- Face masks, wipes and cosmetic singles
- Subscription sends through a letterbox
- A lay flat pouch inside a carton as an inner
- Not for shelf display, where standing wins
- Three side seal the standard lay flat pouch we run
- Four side seal sealed on every edge
- Pillow pouch a back seam rather than side seals
- Sachet format small single dose pouches
- With a tear notch opening without scissors
- Window lay flat pouch product visible behind film
Sizes We Print Regular
Every lay flat pouch is built to your fill, though these run often:
- 5g to 20g for single serve sachets
- 50g for samples and trial sizes
- 100g for a small retail fill
- 250g for a standard retail pouch
- 500g where flat still works
- Custom sizes matched to your dose
Fill a sample first. Powders settle, and a lay flat pouch sized on loose volume looks underfilled.
Film And Barrier
- PET outer for print quality and strength
- Foil or metallised layer where oxygen matters
- Polyethylene inner for a reliable heat seal
- Kraft outer for a natural look
- Mono material PE on a recyclable lay flat pouch
- Food grade certified film throughout
Seal width matters more here. With no gusset absorbing stress, a lay flat pouch puts everything on the edge seals.
Being Straight About Recycling
- A mono material lay flat pouch recycles normally
- Foil laminates give the best barrier, worst recycling
- A compostable lay flat pouch suits some products
- Less film per unit than any gusseted format
- Soy based ink through the whole run
- Right sizing so nothing is wasted per pouch
A lay flat pouch already uses less material than a stand up, which is a real reduction before film choice.
How An Order Runs With Us
- 100 unit minimum, so a small brand can launch
- Free 3D mockup and proof before printing
- Free artwork setup by our designer
- Physical sample, filled and sealed
- Urgent turnaround at 5 to 8 business days
- Free worldwide shipping included
Frequently Asked Questions
Why a lay flat pouch over stand up?
Cost and postage. It uses less film and posts in a cheaper band.
Will a lay flat pouch stand on a shelf?
No, and that is the trade off. For display we would move you to a stand up.
Can a lay flat pouch be resealed?
With a zipper, though it adds cost. Most are single use by design.
Which seal width do you use?
Generous, since the edges carry everything. Narrow seals are where a lay flat pouch fails.
Is it letterbox friendly?
Usually, depending on fill depth. Send the carrier limit and we build a lay flat pouch inside it.
How much does a lay flat pouch cost?
Rough estimate is $0.04 to $0.12 on a simple structure, $0.08 to $0.20 with foil barrier and $0.03 to $0.08 for sachets at moderate volume. Shipping is included. This is estimate only, so ask us for a exact quote.
Can you do single serve sachets?
Down to a few grams. Sachets are our most common lay flat pouch format.
