Side Gusset Pouch

Side gusset bags are one of the most trusted and versatile packaging formats used across industries today. Designed to offer excellent shelf presence, increased capacity, and long-term product protection, side gusset packaging products are ideal for brands that need functional packaging without compromising aesthetics.

At Aropack, we offer side gusset pouches that are a cost-effective, flexible packaging option for a wide range of products, particularly bulkier items.

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custom printed side gusset pouch packaging bag

Key Benefits of Side Gusset Pouch

Designed to accommodate large volumes and support heavy weights, side gusset pouches are the industry standard for bulk storage and transport, minimising the risk of product damage during transit. While reseal zippers are not an option due to the gusset folds, reseal stickers or tin ties can be used, and valves can be added for coffee packaging.

Cost-Effective & Lightweight

Recyclable structures available

Variable side gusset formats

Product window, gloss or matte finishes

Tear notches and laser scoring

Reliable protection during transport

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Technical Overview

Why choose side gusset pouch?

A side gusset pouch gives you four clear faces for branding, ingredients and other information, so ranges stay easy to read and consistent. With custom print options, it’s possible to control colours and finishes while the pack could be opened easily and poured cleanly for the end user. If you need side-gusset coffee bags tailored to your brand, we have the right options for you.

When filled, the side panels expand evenly, providing strength and making the shelf display look attractive. Compared to flat pouches, side gusset packaging offers improved storage efficiency and a premium look.

Because the side panels are folded flat until filling, you can fit more product into side gusset bags through their slimmer footprint. The gussets expand as the pouch fills, which creates strong shelf presence and helps to reduce packaging material while keeping the product safe through handling and transport.

Proud to be trusted by start-ups, SMEs, and global brands alike.

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Technical Overview: Side Gusset Packaging

Side gusset pouch packaging is efficient to ship and store because it arrives flat and weighs less than rigid tubs for the same fill. It works across coffee, pet food, snacks and dry mixes. Their shape, combined with a K seal at the bottom, gives extra strength and stability for heavier fills. With the right film structure and seal design, they can be customised to hold up to around 20 kg of product. Our side gusset packaging has become a preferred choice due to its durability and premium appearance.

Here’s the complete range of features built into our side gusset bags:

Sizes

Available in sizes ranging from 100g to 20kg.

Finish

Matt, gloss, paper touch, de-metalized, unprinted and spot finish.

Film Properties

Available with oxygen, moisture, light and puncture barriers.

Filling & Sealing

Heat sealable and suitable for hot and cold filling.

Materials

Recyclable mono materials as well as multi-layer laminates.

Printing

Digital, flexo and gravure print up to 9 colours.

Our side gusset pouches can be customised with:

Sealing Options

Zipper, Peel Seal, Top Sliders, Child-Resistant, Aplix

Laser Scoring

Effortless opening, ideal for sturdy & thicker materials

Rounded Corners

Enhance shelf appeal, improve safety, and ease handling

Handles

Easy to Carry: side handles, top handles, euro-slots

Perforations

Allows airflow while maintaining breathability

Windows

Clear or frosted windows

High Barrier Films

Extends shelf life and keeps product safe

Tear Notch

Easy-to-open for convenient consumption

Eco-Friendly Side Gusset Pouch

At Aropack, we work with our clients from material selection through to final custom printed side gusset pouches. Our eco-friendly gusseted bags are made of mono-material laminates as PE/PE or PP/PP.

We also integrate EVOH layers in our recyclable packaging to provide enhanced oxygen protection. These structures remain compatible with the UK’s recycling stream and align with OPRL guidance and local collection capabilities. However, we always advise to check local kerbside recycling availability, as collection systems can vary across the UK.

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Industries Using Side Gusset Pouch Packaging

Our side gusset pouches are designed to meet the unique needs of industries and applications, from food and pet food to health, beauty, and beyond. Whether you need side gusset coffee bags or pet food packaging that looks attractive, we have a premium range of products for your needs.

Sports & Nutrition

Preserves the quality of products like protein powders, energy bars, and supplements, ensuring users receive optimal support for their training and performance.

Pet Food

Ensuring the nutritional integrity of items like kibble, treats, and supplements, pet owners rely on quality to provide their pets with balanced meals for well-being.

Coffee

The quality of coffee over time is heavily influenced by its packaging; hence, the role of coffee packaging is crucial in ensuring customer satisfaction.

Health & Beauty

Designed to preserve the excellence of skincare, cosmetics, and personal care essentials, ensuring you indulge in the finest products.

Confectionery

Packaging for candies, chocolates, and treats, making every moment a delightful and memorable experience.

Snacks

Our packaging for snacks and nuts are crafted to preserve freshness and crunchiness, delivering a premium taste.

Frozen Foods

Prioritising the extension of shelf life and minimising freezer burn is crucial, with the added benefit of user-friendly sealing.

Jerky

Savour the flavour with our jerky packaging, ensuring every bite is a mouthwatering experience of perfection.

Cannabis

It is essential to protect the quality of cannabis products and ensure consumers enjoy the full benefits.

Got questions about side gusset pouch?

Here are some of the most common queries we get about our custom printed side gusset bags.

Have a different question?

Yes. Side gusset coffee bags are a long standing format in the industry. They work well with one way degassing valves and high barrier laminates so aroma, flavour and freshness are protected from roasting through to the end of shelf life.

Yes. We can adjust the structures with strong protection against moisture, oxygen and light. Options include metalised films, EVOH based barriers and other high barrier layers, chosen around your product sensitivity and shelf life targets.

Both formats have side gussets, but they are constructed differently. A side gusset bag is sealed at the top and bottom with open gussets on the sides. However, a quad seal bag has four vertical corner seals that create a more rigid, box like shape. The choice often comes down to weight, brand style and how you want the pack to sit on shelf and in cases.

Side gusset bags are usually closed with a heat seal after filling, but we can add simple reseal options such as tin ties, reseal stickers or hook to hook closures. These are useful when the product will be opened and closed several times at home.

Yes. We produce recyclable side gusset bags using mono material PE or PP structures. These are designed to support current recycling routes while still giving the print quality, machinability and barrier performance needed for everyday use.

Yes. We can adapt the base to create a more square or block bottom style side gusset bag. This can improve volume, help the pack stand more firmly and give a better presentation on shelf and in outer cases.

When filled, side gusset bags form a compact, brick like shape with tight side folds. This helps them stack closely together in cases and on pallets, which usually gives better pallet efficiency than many stand up pouch formats, especially for export or central warehousing.

View other options

Flat Bottom Pouch

3-Side Seal (Flat) Pouch

Spout Pouch

Aropack compostable stand-up pouch with TÜV Austria certification—ideal for sustainable and eco-friendly packaging.

Compostable Packaging

Flow Wrap Film