Custom Side Gusset Pouch

Expandable. Efficient. Eye-Catching.

Side gusset pouches feature gussets on each side that expand as the pouch fills, allowing more storage without bulking up the package. Ideal for coffee, protein powder, pet food, snacks, and more, these pouches offer great strength and visual real estate.

Materials

Our material selection guarantees product safety, long shelf life, and eco-conscious options.

• PET/PE laminates – Durable and moisture-resistant for food or supplements
• Foil-based films – Light and oxygen barriers for extended freshness
• Kraft/paper laminates – Sustainable, rustic look with protective layers
• Recyclable films – Eco-friendly solutions for conscious brands

Sizes

Every pouch is tailored to suit your product and industry requirements.

• Compact sizes for snacks, spices, and samples
• Medium sizes for coffee beans, rice, or cereals
• Large formats for bulk pet food or garden supplies
• Custom widths, gusset depths, and fill volumes available

Printing

Your branding shines on both side gussets and front/back panels.

• CMYK and Pantone printing for vibrant visuals
• Glossy, matte, or soft-touch lamination
• Foil stamping, embossing, or spot UV for high-end appeal
• Clear windows to show the product inside

Add-ons

Elevate function and user convenience with thoughtful features.

• Resealable zippers or Velcro closures
• Easy-tear notches and heat-sealed edges
• Degassing valves for coffee freshness
• Hang holes and custom tear shapes

The 3Ps Approach

Presentation

With bold print coverage on all four panels, side gusset pouches offer maximum branding space and visual shelf impact.

Preservation

High-barrier laminates protect against moisture, air, and UV rays—ensuring your product stays fresh and flavourful.

Protection

Reinforced seals and sturdy construction make these pouches ideal for heavier contents and rough transit, preventing damage and contamination.

Why Choose Custom Boxes Lab?

Over 5,000 businesses trust us for packaging that meets industry standards while enhancing brand identity.

• FDA-compliant, food-grade materials
• Low MOQs and bulk discounts
• Free layout support and digital mockups
• Fast turnarounds and US-wide delivery
• Responsive customer service team

Get a Quote Today

Upgrade your packaging to a pouch that stores more and stands out. To get cost-effective packaging boxes without compromising on quality, you can contact us at (469) 649-8706 or email us sales@customboxeslab.com

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.