How to Choose the Right Size Custom Pouch

Learn how to choose the right custom packaging size for your product. Getting packaging that's too small or too big will cost you on all fronts and make your customers question what they purchased. 

Right-sizing is a commonly used term in the packaging industry. It's the process of constructing well-fitted packaging for the contents of the package while still providing enough protection for the product.

You, the manufacturer, and your customer benefit from right-sizing since it reduces costs and minimizes waste. It also improves the unboxing experience, creating an excellent first impression for your customers.

The impact of online stores like Amazon, Alibaba, Walmart, and individual companies that ship directly to the consumer is driving demand for right-sized packaging. It's what customers, businesses, and logistics firms want.

Both oversized and undersized packaging may have far-reaching and severe consequences for businesses.

  • Oversized packaging causes material wastage, makes things heavier to transport and store, and consumers may find it cumbersome to handle. This may irritate your customers and hinder repeat purchases.
  • Still, insufficient packaging provides insufficient protection, and goods are often damaged during transportation.

The Importance of Right-Sizing Your Packaging Pouches

What is the real meaning of right-sizing, and why is it so important? As silly as it may sound, right-sizing a package is not only about selecting the appropriate package size for your product.

Right-sizing also entails assessing your product's shape, material, and susceptibility and choosing the best packaging option.

This is essential not only for the ultimate cost of the product in your customers' hands. It's also for the projected environmental effect of the packaging and its capacity to preserve and protect your products from external elements based on the shipping mode you choose.

Because of the misconception that 'bigger is always better,' some manufacturers overpackage in an attempt to maximize branding space and offer higher perceived value. However, this results in one major drawback: increased warehousing and shipping costs decrease the product's margins.

Here are ways in which right-sizing your package can benefit you.

1. Boost Consumer Satisfaction

It has often been said that good things come in small packages, which might be truer here.

Consumers often form a negative opinion of a brand that uses excessive, difficult-to-handle, and wasteful packaging. Having properly packaged products demonstrates to your customers that you care about their needs and the environment.

2. Reduce Your Carbon Footprint

Right-sizing a product package reduces excess in both material and waste.

Choosing the appropriate size also minimizes the amount of space the products occupy in the freight vehicle, lowering the shipment's carbon impact.

3. Improved Protection

When it comes to product protection during transit, bigger is not necessarily better.

Large packages have more vacant space to fill, which increases the likelihood of a product moving around inside the box. The proper packaging size will protect the goods with no need to double or triple its size.

4. Lower Your Shipping Expenses

Finding packaging that properly fits your product will reduce your DIM weight and save you money on delivery.

DIM weight is a formula used by shipping firms to calculate the dimensional weight of your packaging. The greater the DIM weight, the more costly shipping will be for your delivery. 

Who Benefits from Sustainable Packaging?

Despite differing views on environmentalism in the United States and Europe, everyone generally welcomes sustainable packaging.

In a nutshell, everyone prefers environmentally friendly packaging. Right-sizing your packaging supports sustainability by eliminating or minimizing the need for foam and plastic while utilizing the least amount of materials possible, and therefore reducing waste.

  • Customers prefer that companies ship in more efficient packages. The concept of "shipping air" has caused consumers to expect guilt-free and frustration-free packaging from their brick-and-mortar and online stores, such as Walmart and Amazon.
  • Retailers desire a more appealing customer unboxing experience, convenient packaging not just for the consumer but also to reduce waste, occupy less inventory space, and be delivered safely to the end consumer.
  • Shipping and logistics organizations encourage brands to ship small packages. Right-sizing started with optimizing package sizes for sea containers to reduce transportation costs for items moving from Asia to North America. Smaller packages take up less space, allowing logistics businesses like Amazon, FedEx, and UPS to send out more goods per shipment every day. The need for right-sized packaging in the shipping and logistics industries is driven by efficiency and cost reductions.

But Why Do Businesses Ship Small Products in Big Packages?

One specific problem for brands and businesses in right-sizing packages is that there are instances when smaller things must be shipped in oversized packaging, particularly in eCommerce.

An article on SearchERP headlined "E-commerce Packaging Waste Becoming a Bigger Issue" reads that eCommerce packaging and delivery are considerably different from regular retail.

Throughout a standard retail scenario, products are handled five times on average and 20 or more times in the eCommerce process, and eCommerce's high number of interactions requires clever packaging.

For instance, one eCommerce business found that couriers dropped the average product 17 times throughout the delivery process. While bigger boxes consume more resources and generate more waste, the extra space within the package allows shippers to wrap things using protective cushioning and air to minimize damage during transit.

Nonetheless, the modern customer demands that brands be eco-friendly and sustainable. Customers are willing to discuss their cardboard footprints, not carbon footprint, and they expect packaging that creates less wrap rage.

Optimizing your packaging size is less wasteful and cuts down your working budget, so it's a win-win situation.

But how do you choose the right sized packaging?

How to Right-Size Your Custom Packaging Pouches

It is not too difficult to choose the right pouch size, but it does take knowledge of the measurements and functions you desire in your pouch. 

The right size custom pouch protects your products from damage while also allowing them to stand out on retail shelves and reducing packaging costs.

When considering how to determine your pouch size, there are two factors to keep in mind. Firstly, the order of pouch measurements is always as follows: width, height, and gusset (meaning if you see a third dimension, you know the bag has a gusset.)

To obtain an accurate reading when sizing a gusseted bag, open the pouch and measure from front to rear on the underside of the pouch.

*It's worth noting that some manufacturers regard half of the measured length as the gusset size, while others consider the whole gusset length as the right dimension.

Second, as illustrated below, pouch measurements are always predicated on outer dimensions.

But here's the thing: there's a distinction between the pouch's reported size and its real fillable space. For example, a pouch size 5 x 6inches, for example, will not always accommodate a product measuring 3 x 5 inches. This is why it's necessary to test it first with your own product.

Also, remember that zippers, seal measurements, tear notches, and hang holes are included in the total package dimensions and might affect the "fillable" space. The fillable space is the pouch area that extends from the zipper or heat seal line to the bottom.

Here are two things to consider to ensure that your pouch is the right fit for your product.

Product Volume

Knowing the volume of your product is extremely important when selecting the appropriate pouch size.

For instance, an item of six ounces of dense food, such as meat, use up less volume than six ounces of granola, which is bulky yet light.

Some bulkier products may even necessitate using a bigger pouch to handle the additional volume, so test your product in several pouch sizes before ordering.

Filling Method

Another critical factor to consider is what kind of packaging and filling equipment you'll be using. You may be filling pouches manually, but if you're automating your operation, there are a few things to keep in mind. 

The thickness, size, and kind of packaging materials you require will determine how you package your products. 

One reason is that an automatic filler will exert more force than a manual filler. Thus, you must ensure that your equipment does not compromise the pouch during operation.

At Pouch ME, our packaging specialists and designers are pleased to talk about different packaging processes and how to choose the right pouch size and thickness for the job.

Can I Use a Pouch Size Calculator?

While a pouch size calculator may appear to be a straightforward option for determining your optimum pouch size, it is not.

Each product and application is different, and this variety usually necessitates trial and error to achieve the ideal package fit.

The size principles we discussed above are a wonderful place to start when determining the volume of your product and how much a pouch can accommodate.

Another smart way to start is by experimenting with pouch designs at home.

  • First, look for a bag on your shelf that contains a comparable product.
  • Then, to obtain an estimate of the bag size you require, empty the pouch contents and fill it with your product.
  • Alternatively, you may go to any food store and buy the sort of pouch that is appropriate for your product and test filling it with your own product for comparison.

Your Quick Guide to Standard Pouch Sizes

At Pouch ME, we can meet all standard pouch size requirements and custom pouch sizes.

Any of these standard bag sizes could be ideal for you. Having said that, every product is unique and therefore has precise requirements for safety reasons.

This pouch size chart will give you an idea of what we offer in terms of standard pouch sizes.

Right-Sizing Your Custom Pouch Packaging Perfectly With the Latest Printing Technologies

If the standard-sized pouches in the chart have no size that is suitable for your one-of-a-kind product, you don't need to worry. We can make a custom pouch sized to any dimension you require. Whatever product you need to package, we have the custom packaging solution fit for you.

How to Choose the Right Size Custom Pouch?

If you're still confused or aren't confident about doing this on your own, reach out to us and we'll consult for free.

Day in day out, our packaging specialists work with small to large businesses to design custom-sized pouches. You simply submit a request (NEED TO LINK TO CONSULT) and they will do the same for you. 

Custom printed pouches ensure that your product is delivered in the safest and most professional, stand-out packaging possible and in the correct size.


- Choosing the Right-Size Packaging Pouch FAQs -

  • How do you know what pouch size to get?

Because it's so tricky to standardize based on any packaging pouch's size and its actual fillable space, it's essential to test a pouch with your own product. This is if you aren't consulting with a packaging firm and doing this on your own.

A way to do this is to get the weight and volume of your product, go to a supermarket and see comparable products, purchase those products and empty the contents. Test, test, test!

Once you're happy with a sample, measure the below and save for reference to show to your print packaging provider:

Width: measure the distance between the pouch's outside left and right edges

Height: measure from the outer bottom border to the very top of the packaging pouch

Bottom Gusset: measure the distance between the pouch's exterior bottom edge, and the maximum depth of the interior fold is two times its length

  • How much will a stand-up pouch hold?

A pouch's holding capacity varies for a solid substance vs. a wet product. However, a basic estimate of holding capacity informs us that a bag with dimensions of 3 x 5 x 2 can carry 1 ounce of dry goods but 3 ounces of liquid.

  • How do you properly package a product for shipping?

To package your product, these are the steps to follow:

1. Assess your product's requirements and choose the suitable packaging material

2. Wrap each item separately if your package contains multiple separate products

3. Avoid leaving an empty space inside the package and do not overstuff

  • How do you calculate the volume of a pouch?

This is the working formula: V = L x W x H

Calculate the volume by multiplying the length, width, and height measurements. 

Take three measurements to get the volume of your packaging pouch. 

1. The first measurement should be the width across the pouch's entrance. 

2. The second measurement is the gusset's depth, measured by completely extending the gusset.

3. The third and last measurement is the length of the bag from its opening to the bottom.

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