Side Gusset Bags.

The gussets are pleats folded into both sides that open out as the bag fills, so depth comes from the fold rather than from a wider front panel. A flat pouch of the same face size holds a fraction of the volume. The gusseted version takes 250 g, 500 g or 1 kg of coffee in a pack that still sits neatly on a shelf.

Film use is lower than a flat bottom bag, which is where the cost advantage comes from.

Not reliably, and it is better to plan merchandising around that than to be surprised by it. With no bottom gusset the base is a fold, so the bag stands when full and leans once it is part-filled or has been handled. Roasteries display them in trays or on their side for that reason.

A block bottom turns the same construction into a pack that stands square. If standing matters, ask us to quote both and compare.

Welded into the front panel, which is the standard position for coffee. Freshly roasted beans give off carbon dioxide for days after packing, and without a one-way vent the bag inflates and the seals stress. The valve lets gas out and nothing in.

Foil structures can also be vacuum packed into a rigid brick, which is the other way coffee gets shipped in this format. Tin-tie is the traditional reclose for a roastery bag, and a zipper is the alternative where the customer opens it daily.

Matte lamination is the speciality coffee standard, and a kraft outer is the single most recognisable look in the category. Gloss lamination makes the print colours richer and is the usual pick for supermarket and value coffee ranges. Hot foil stamping adds metallic detail on single-origin ranges.

A metallic reveal leaves areas unprinted so the foil shows through as silver. A clear window showing bean, grind or leaf is a real purchase factor in coffee and tea, and it sits on the front panel alongside the valve.

Width by length plus the gusset depth on each side, and never as a length by width by height box dimension. A 4 x 10 inch bag with a 2.5 inch gusset takes around 250 g of coffee, and 6 x 14 inches with a 3.5 inch gusset suits 1 kg.

Roast density varies, so we settle a filled sample before fixing the size. Bulk and food service formats run larger on a heavier gauge film, since the settled weight loads the base seal.

The minimum is 500 bags per size and design. A valve, tin-tie or window is added per unit and does not move that floor. Prices step down beyond 1,000 pieces.

Runs scale to 100,000 without changing the laminate. Roasteries commonly start a new blend at the minimum and consolidate sizes onto one order as the range settles, since each size still has to meet its own minimum.

Standard production is 7 to 10 business days, and a rush order is 5 to 7 business days. Samples are 5 to 7 business days and the sample fee is credited when the bulk order goes ahead.

Pack a sample with fresh roast and leave it a week. If the valve is doing its job the bag stays flat, and if the seals are right nothing escapes but the gas. That tells you more than any spec sheet.

PET, aluminium foil and PE is the coffee default: full barrier, and the structure that vacuum-packs into a rigid brick. The BOPP, metallised PET and LLDPE laminate gives a metallised barrier at lower cost and is right for tea, dry goods and pet food.

Kraft over PE gives the paper face speciality and single-origin coffee is known for. On larger fills and abrasive contents we move to a heavier gauge film, because the settled weight sits on the base seal.