Custom Flat Pouches

Will my sample flat pouch match the bulk order?

Yes, more closely than most suppliers. Many factories proof on a digital printer, which drifts from the final result. We proof on the same production process that runs your bulk order, so the sample matches the production result with only minor batch variation. Our sample fee is a little higher for that reason, and it's worth it.

Which zipper should I choose for my pouch?

A Standard Zipper is a familiar choice for everyday resealing. For fine or dusty products, a Powder-Proof Zipper helps the pouch open and reclose more smoothly.

Which material gives the longest shelf life?

Classic with High Barrier gives the longest shelf life. Classic is metallized for strong moisture and oxygen protection, and High Barrier adds a foil layer for the most sensitive contents like supplements and freshness-critical powders. Recyclable and Compostable suit shorter shelf-life or lighter-protection products.

What sizes do flat pouches come in?

Flat pouches come in small standard sizes built for samples and single servings, such as 3.5 x 5 inches, and you can set a fully custom size for your exact fill (in inches or millimeters). We fully customize dimensions, so build your size in the 3D quote tool and see the price instantly. Keep in mind the inside space is a little smaller than the outside dimensions, so size to your product, not the flat measurement.

What seal width options do you offer?

Three: Narrow, Standard, and Wide. Narrow is 5mm, Standard is 6mm, and Wide is 7.5mm. The seal is the sealed border around the pouch. Narrow gives a sleeker, more minimal edge, Standard is the everyday default, and Wide is a wider, more durable seal for heavier fills. Pick by your product weight and the look you want.

What's the minimum order for custom flat pouches?

100 pouches. That's low enough for a sample program, a first launch, or a market test, with wholesale and bulk pricing as you scale. The unit cost drops at each quantity tier as you build your order.

What products are suitable for the PCR Material option?

The PCR Material option is best suited for lightweight dry products such as coffee, snacks, powders, and dry pet food, with a recommended filled weight of up to 1 kg. It is not recommended for liquids or heavy-duty applications. Final suitability depends on the product, filling conditions, and packaging requirements.

What is the PCR Material option?

PCR stands for post-consumer recycled. Our PCR Material option replaces the standard PE layer with an 80 μm PE layer containing 50% post-consumer recycled content, helping reduce the use of virgin plastic. It is available with eligible Classic and Recyclable structures. Eligible pouch structures contain approximately 30% PCR by total finished-package weight. The final percentage varies based on the selected structure and components and can be confirmed for the final pouch specification.

What is a flat pouch, or sachet?

A flat pouch is a slim three-side seal pouch with two flat printable panels, also called a sachet, sample packet, or single-serve pouch. It's compact, tears open easily, and keeps a low per-unit cost, which makes it the go-to for cosmetic samples, single-dose supplements, powders, condiments, and on-the-go servings. The flat shape prints cleanly and packs neatly into cartons and subscription boxes.

What if my flat pouches arrive damaged or wrong?

Reach out to our team within 24h of delivery. If the order is damaged, defective, or doesn't match the approved proof, we'll review it and make it right.

Matte, gloss, or soft touch: what lamination can I add?

All three. Matte gives a smooth, low-glare finish, Gloss gives a shiny, vibrant finish, and Soft Touch Film gives a velvety, premium feel. Lamination sets the surface look and feel of the finished pouch.

How much do custom flat pouches cost?

Price depends on pouch size, order quantity, material and barrier level, lamination, finishing effects (Spot UV, Hot Foil, Window), seal width (Narrow is 5mm, Standard is 6mm, and Wide is 7.5mm), and add-ons like a tear notch, zipper, or hang hole, plus shipping. Larger quantities lower the unit cost, while High Barrier and added options raise it. The 3D quote tool updates your landed price live as you build, so there are no surprises.

How long do custom flat pouches take to make and ship?

Production takes 7 to 12 business days after proof approval. Shipping then depends on your tier: Express is fastest at about a week, with Priority, Standard, and Economy at lower cost and longer transit. Exact timelines show as you build your order.

How does a Powder-Proof Zipper help with powdered products?

Fine powders can enter standard zipper tracks. A Powder-Proof Zipper is designed to keep opening and closing smoothly when particles reach the zipper area. It works well for protein powders, supplements, flour, spices, drink mixes, and similar products.

How do I choose the right material for my flat pouch?

Start with what matters most. Classic is a metallized film with the strongest moisture and oxygen barrier, the safe pick for samples of sensitive or premium products. For the most demanding contents, turn on High Barrier, which adds an aluminum foil layer for even stronger protection. Choose Recyclable if a recycling-friendly direction matters to your brand: a mono-material PE film with an EVOH barrier, designed for the PE recycling stream. Choose Compostable if sustainability storytelling matters most: kraft and PLA for products with lighter protection needs.

How closely does the 3D preview match the finished pouch?

Closely. It's a true-to-spec view of your size, material, finishing, add-ons, and artwork, and a reliable guide for decisions. Small color and finish differences can still appear in print, so order a custom sample to confirm the exact look before a full run.

How accurate are the printed colors on custom flat pouches?

We match to spec with CMYK and Pantone references, so your brand colors stay consistent across runs. Screens and print can differ slightly, so order a custom sample if exact color is critical.

Does PCR material make a pouch recyclable?

Not necessarily. PCR describes the recycled content used in the pouch, not whether the finished package can be recycled. Classic pouches with PCR remain multilayer packaging and are not recyclable. For a structure designed for PE recycling streams, choose the Recyclable material option and enable With PCR. Actual acceptance varies by location and recycling program.

Can I see what my flat pouch will look like before I order?

Yes. The 3D preview applies your size, material, lamination, finishing, add-ons, and artwork to the actual pouch, so you can rotate it and review the finished look before committing.

Can I reorder the same flat pouch design later?

Yes, in one click. Your approved designs are saved to your account, so repeat runs use your locked specs and artwork with no rebuilding or re-proofing. Pricing reflects the new quantity and options you choose.

Can I order a sample flat pouch before placing a full order?

Yes. A custom sample is made with the same material, printing, and finishes as your full order. It arrives in about two weeks, and you also get 10 white-background product photos around Day 10, so you can start marketing before it lands.

Can I design my flat pouch without a dieline?

Yes. Use the 3D quote tool to build the pouch and your options, then upload artwork. If you already have a dieline or finished art, upload it directly. You don't need to understand every file requirement to move forward.

Can I add finishing like Spot UV or Hot Foil?

Yes. The Finishing Effects let you make specific areas stand out: Spot UV adds glossy highlights on areas like your logo, while Hot Foil adds a metallic shine. These sit on top of your full-color print for a premium accent.

Can I add a tear notch for easy opening?

Yes. A tear notch is a small cut at the seal edge that lets customers tear the sachet open cleanly by hand, with no scissors needed. It's worth adding for any single-serve product people open on the go.

Can I add a resealable zipper to a flat pouch?

Yes. A Standard Zipper turns the pouch into a resealable pack, so customers can open and close it multiple times. It's worth adding for multi-use powders, snacks, or sample sets, and less necessary for true single-use sachets.

Can I add a hang hole for retail display?

Yes. You can add a Euro Hang Hole or a Round Hang Hole so the pouch hangs cleanly on a retail peg or display strip. It's a small detail that makes the pouch shelf-ready for in-store merchandising.

Can I add a clear window to show the product?

Yes. A clear window, set in the Finishing Effects, lets customers see what's inside, which works well for colorful powders, bath salts, and sample creams. Skip it if your product is light-sensitive or you want full-coverage print across the panel.

Are flat pouch sachets food-safe?

Yes. The inner layers are designed to meet FDA food-contact requirements, and ink is printed outside the food-contact surface, away from your product. FDA food-contact compliance documentation is available in the Product Details section.