Stand-Up Pouch Size Guide by Fill Weight: 100 g, 250 g, 500 g and 1 kg
Quick answer
There is no single correct pouch size for a fill weight, because size depends on how much space your product takes up (its bulk density), not on grams alone. As a starting point for a medium-density dry product, a 100 g fill is commonly packed in a pouch around 120 × 190 mm with a 70 mm bottom gusset, 250 g around 140 × 220 mm + 80 mm, 500 g around 170 × 260 mm + 90 mm, and 1 kg around 220 × 320 mm + 120 mm. Treat these as shortlists, then confirm the size by filling a blank sample with your real product.
Quick facts: Custom Printed Stand-Up Pouches
- Indicative unit price: about US$0.05–0.10 per piece. This is a guide, not a quotation: the final price depends on size, material, print colours, finish and order quantity.
- MOQ: typically from 500 pcs per size and artwork; the confirmed minimum depends on material, print method and features and is stated on the quotation.
- Lead time: Physical samples 5–7 working days after artwork is confirmed; bulk production 20–30 days after sample approval.
- Who makes it: BestPackFactory’s own factory in Longhua District, Shenzhen, China. Free dieline and artwork proof within 24 hours. See real samples and videos.
- Specifications and quote: Custom Printed Stand-Up Pouches · Request a quote
Typical starting sizes by fill weight
The ranges below are commonly used starting points for a medium-density dry product (for example granola, nuts or whole coffee beans packed loosely). Dimensions are width × height + total bottom gusset, in millimetres. Suppliers state sizes differently, so confirm how your supplier measures before comparing quotes.
| Fill weight | Typical width | Typical height | Typical bottom gusset | Notes |
|---|---|---|---|---|
| 100 g | 110–130 mm | 170–200 mm | 60–80 mm | Sample, trial and single-serve retail sizes |
| 250 g | 130–160 mm | 210–240 mm | 70–90 mm | Most common retail size for coffee, snacks and supplements |
| 500 g | 160–190 mm | 230–280 mm | 90–110 mm | Check that the pouch still stands well when half empty |
| 1 kg | 180–240 mm | 280–340 mm | 90–130 mm | Consider thicker film, a stronger zipper or a flat-bottom format |
If your product is much denser or much lighter than this reference, move up or down a size before you request samples. The next section explains how to judge that.
Why density decides the size, not grams
A pouch holds a volume. Grams only tell you the size once you know how much volume each gram occupies. The useful number is bulk density: the weight of a loosely filled litre of your product, including the air between pieces.
- Dense products such as sugar, salt, rice or fine powders typically weigh roughly 0.7–0.9 kg per litre. They usually fit one size smaller than the table.
- Medium products such as whole coffee beans, nuts or granola often fall roughly in the 0.35–0.6 kg per litre range. The table is aimed at this group.
- Light products such as puffed snacks, dried herbs, loose-leaf tea or freeze-dried fruit can be well under 0.3 kg per litre. They commonly need one or two sizes larger, or a pouch with a deeper gusset.
Particle shape matters too. Long, irregular pieces (dried fruit slices, jerky, pasta) leave more air than round ones and need more headspace than their density alone suggests.
How to estimate the size yourself in five steps
- Measure bulk density. Pour your product loosely into a measuring jug up to 1 litre without tapping it down, then weigh it. Repeat three times and average.
- Calculate fill volume. Divide the fill weight by the density. For example, 500 g of a product weighing 0.45 kg per litre needs about 1.1 litres of space.
- Add headspace. Leave space between the product and the zipper so the zipper can close cleanly and the top seal is not contaminated. Many brands allow roughly 20–30 mm above the fill line, more for powders.
- Allow for seals and the zipper. Side seals, the top seal and the zipper band reduce the usable area. The zipper commonly sits around 30–40 mm below the top edge, and everything above it is not fill space.
- Shortlist two sizes that bracket your estimate and request blank samples of both for a fill test.
Fill-test before you approve artwork
A calculation narrows the choice; a fill test confirms it. Ask for unprinted or stock samples in the same width and gusset you plan to order, then:
- Fill each sample with the real product at the exact target weight, using the same method you will use in production (hand scoop, auger or weigher).
- Close the zipper and check that it seals without product caught in the tracks.
- Stand the pouch on a flat surface. It should stand upright without leaning, and should still stand reasonably when partly used.
- Check how the front panel looks when full: a very slack pouch looks under-filled on the shelf, while an over-stuffed one bulges and distorts the artwork.
- Let the filled pouch settle for a day or shake it gently. Many products settle, which changes the visible fill line.
- If you use a filling machine, confirm that the pouch opening clears the filling spout or funnel.
Record the approved width, height, gusset, zipper position and fill line. That approved sample becomes the reference for the dieline and the purchase order.
Decision rules
- Choose the smaller size when the fill test shows the product reaches close to the zipper with only modest headspace and the pouch still stands well. Smaller pouches use less film and look fuller on the shelf.
- Choose the larger size when the product is light, irregular or fragile, when a scoop must fit inside, or when the zipper is hard to close at the smaller size.
- Deepen the gusset rather than the height when the pouch tips over; a wider base usually improves stability more than extra height.
- Consider another format for heavier fills, typically around 1 kg and above, where a flat-bottom pouch often stands and stacks better. See our separate flat-bottom bag vs stand-up pouch comparison.
What to send in your RFQ
- Product name and form (powder, granules, pieces, liquid)
- Target fill weight per pouch and your measured bulk density
- Preferred size (W × H + bottom gusset) or a request for size recommendations
- Reclosure, valve, window, tear notch and hang hole requirements
- Barrier needs and material preference (clear, kraft, metallised, foil)
- Filling method: by hand or on a machine, with the machine model if known
- Quantity per design and number of designs
Once size is fixed, download the stand-up pouch dieline and place your artwork inside the safe zones for seals and the zipper.
Common sizing mistakes
- Copying another brand's pouch without knowing what product and density it was sized for.
- Comparing quotes with different gusset conventions. One supplier may quote the total unfolded gusset, another the folded depth; the same "size" can hold different volumes.
- Ignoring the zipper position. Space above the zipper cannot be filled.
- Skipping the settle test, then finding the fill line looks low on the shelf.
- Sizing at the target weight only. If your filling tolerance runs over, make sure the upper limit still fits.
Frequently asked questions
What size pouch do I need for 250 g of product?
For a medium-density dry product, a 250 g fill commonly fits a pouch around 130–160 mm wide, 210–240 mm high with a 70–90 mm bottom gusset. Dense powders may fit smaller and light products larger, so confirm with a fill test on a blank sample.
Why does the same pouch hold different weights of different products?
A pouch holds a fixed volume. Products with a lower bulk density, such as puffed snacks or loose-leaf tea, fill that volume with fewer grams than dense products such as sugar or rice.
How much headspace should I leave in a stand-up pouch?
Many brands leave roughly 20–30 mm between the product and the zipper so it closes cleanly, and more for fine powders. Confirm the right amount on a filled sample.
How do I confirm the pouch size before ordering?
Request blank samples in two candidate sizes, fill them with your real product at the target weight, close the zipper, check that the pouch stands and looks full, and record the approved dimensions for the dieline.
Related pages
Prepare a quote-ready packaging brief
Send your product type, fill weight, measured bulk density, preferred size, reclosure and quantity. BestPackFactory quotes custom packaging as B2B projects with a site-wide MOQ of 500 PCS. Reach Lisa Wu at lisa@colorprintingpackage.com or WhatsApp +86 158 8653 0985; anything not listed here is confirmed in the quotation.
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