Side gusset pouches are a cost effective flexible packaging option for a wide range of products, particularly bulkier items. 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.
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.
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.
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.
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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. Here’s the complete range of features built into our side gusset bags:
Available in sizes ranging from 100g to 20kg.
Matt, gloss, paper touch, de-metalized, unprinted and spot finish.
Available with oxygen, moisture, light and puncture barriers.
Heat sealable and suitable for hot and cold filling.
Recyclable mono materials as well as multi-layer laminates.
Digital, flexo and gravure print up to 9 colours.
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.
Here are some of the most common queries we get about our custom printed side gusset bags.
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.
Flat Bottom Pouch
3-Side Seal (Flat) Pouch
Spout Pouch
Compostable Packaging
Flow Wrap Film
