Material Structure and Thickness of pouch with gusset

What is a pouch with gusset?

A pouch with a gusset is a flexible packaging bag that includes extra material (the gusset) folded into one or more sides or the bottom. The gusset expands when the pouch is filled, allowing the bag to hold more volume and stand upright more easily.

Main features of pouch with a gusset:

a folded panel at the bottom that opens to create a flat base (common in stand-up pouches).

panels along the sides that expand outward to increase width.

a configuration of multiple gussets creating squared corners for stability and large capacity.

Bottom-gusset pouches can stand on shelves when filled — good for display.

Gussets let a pouch hold bulkier contents without dramatically increasing the flat dimensions of the package.

Usually made from flexible films, laminates, foil, or plastic; sometimes combined with resealable zippers, spouts, or valves.

What does the material structure of a pouch with gusset refer to?

Pouch with gusset is a type of flexible packaging product (i.e., flexible packaging pouch). Like other flexible packaging products, they are made by combining and laminating different types of plastic films. This is one of the three key factors in pricing of pouch with gusset.

What are some commonly used material structure combinations for pouch with gusset? What are their characteristics?

Simply put, the material structure of a pouch with gusset can be divided into three layers: “printing layer,” “barrier layer,” and “contact layer.” Although pouch with gusset can be made by combining and laminating different types of plastic films, it does not mean that these films can be combined into material structures arbitrarily. The following are common material structures suitable for pouch with gusset, based on years of practice.

(Kraft paper)PET/CPP(PE)

PET/CPP. The biggest advantage of this material structure for pouch with gusset is its low cost. When the package capacity exceeds 500g, CPP must be replaced with PE. If it needs to pack powdered products such as coffee, kraft paper needs to replace PET.

MOPP/PET/CPP(PE)

MOPP/PET/CPP. The biggest advantage of this material structure for pouch with gusset is its wide applicability, and the printing layer can be matte finished to make the printing more “classically beautiful.” The contact layers CPP and PE can be alternated according to different packaging contents.

MOPP/VMPET/CPP(PE)

MOPP/VMPET/CPP. The biggest advantage of this material structure for pouch with gusset is its high barrier against sunlight. Combined with matte-finishable MOPP, the “classical beauty” printing effect of the bag’s appearance is even more obvious. The contact layers CPP and PE can be alternated according to different packaging contents.

Kraft paper/VMPET/CPP

Kraft paper/VMPET/CPP. The biggest advantage of this material structure for pouch with gusset is its high barrier against moisture and sunlight, making it very suitable for packaging coffee powder/beans and other products. The contact layers CPP and PE can be alternated according to different packaging contents.

PET/AL/PE(CPP)

PET/AL/PE(CPP). The biggest advantage of this material structure for pouch with gusset is its high barrier against moisture/sunlight/oxygen. The product has wide applicability. The contact layers CPP and PE can be alternated according to different packaging contents, but the price of pouch with gusset made of this material structure is relatively high.

What does the thickness of the material structure in pouch with gusset refer to?

It refers to the total thickness of the “printing layer,” “barrier layer,” and “contact layer” on one side of the pouch. Thickness is measured with calipers at the midsection of the pouch, offset slightly left or right, then divided by two. For example, if the measured value is 248 microns, divided by two equals 124 microns; the net thickness should be considered 120 microns because about 4 microns accounts for adhesive and solvent residue between layers and is excluded from the calculation.

How is the thickness of pouch with gusset material structures determined?

Generally, thickness follows certain standard ranges but is not fixed. It requires adjustment based on the characteristics of the filled product and specific customer requirements:

Email now

300gram-500gram

125-130 microns

600gram-1000gram

135-140 microns

1500gram-2000gram

150-160 microns