- Custom flat pouches (3-side-seal and 4-side-seal packets) have two flat panels welded around the perimeter with no bottom gusset, keeping every packet slim and compact.
- Order tear-open single-serve sachets or add a resealable press-to-close zipper, hang hole and clear peek window for multi-use flat goods.
- Minimums depend on the product and are confirmed with your quote; standard production takes 10 to 14 business days, with 4 to 5 day rush.
- Free design help, custom dielines, zero die or plate charges, a 2D proof and 3D mockup before payment, and free shipping to all 50 US states.
Custom Flat Pouches
Custom flat pouches and 3-side-seal sachets printed edge to edge for single-serve powders, cosmetic sheet masks, jerky slabs, garden seeds, trading cards and trial samples. Minimums depend on the product; we confirm yours with your quote. Ready in 10 to 14 business days (rush in 4 to 5), with free design help and free 50-state shipping.
What are custom flat pouches?
Custom flat pouches are slim, multi-layer flexible barrier packets sealed along the sides and bottom without a folded bottom gusset. Also known as 3-side-seal pouches, 4-side-seal sachets or pillow packets, they lie completely flat inside counter display boxes, subscription mailers and direct-mail envelopes, or hang upright from retail pegboard hooks using a punched header hole. Because they eliminate the extra film fold of a bottom gusset, flat pouches are the most material-efficient way to package single-serve supplement powders, electrolyte drink mixes, cosmetic serum samples, facial sheet masks, flat beef jerky slabs, agricultural seeds and collectible trading cards. Minimums depend on the product; we confirm yours with your quote. At CubitPack, custom flat pouches ship in 10 to 14 business days (4 to 5 days rush) with free design help, no die fees, and free shipping to all 50 states.
Flat pouches facts
- Minimum
- Confirmed with quote
- Turnaround
- 10-14 business days
- Rush
- 4-5 business days, quoted
- Seal styles
- 3-side seal, 4-side sachet, pillow pack, zipper flat
- Printing
- Full color (CMYK), Pantone match, white underbase
- Finishes
- Matte, gloss, soft-touch, spot UV, foil stamping
- Features
- Tear notch, zipper, hang hole, window
- Food contact
- Food-safe inner barrier liners on request
- Shipping
- Free to all 50 states
Which custom flat pouch style should I choose?
| Flat pouch style | Seam construction | Best for | Opening & closure |
|---|---|---|---|
| 3-side-seal flat pouch | Folded along bottom edge, heat-welded along left and right sides | Single-serve powders, tea bags, seeds, trading cards, wipes | Open top for filling + V-cut tear notches |
| Resealable zipper flat pouch | 3-side-seal packet with an upper press-to-close zipper track | Beef jerky slabs, dried mango, gummies, travel toiletries | Tear notches + top heat seal + press-to-close zipper |
| 4-side-seal sachet | Two separate webs welded around all four outer edges | Cosmetic serums, sheet masks, gels, uniform flat packets | Precision laser score + V-notches for clean tear |
| Flat pouch with hang hole | 3-side-seal body with a round or euro-slot punch in top header | Pegboard checkout snacks, phone accessories, hardware kits | Hang hole above zipper or tear-open seal |
| Window flat pouch | Opaque or kraft face with an unprinted clear peek window | Spices, bath salts, artisanal candies, craft supplies | Heat-seal top with optional zipper |
Not sure which style fits?
Request a Quote →What size custom flat pouch do I need?
Flat pouches are measured by outer Width (left to right) × Height (top to bottom) in inches, with no bottom gusset. Side seals take ¼ to ⅜ inch per side, and the top seal (or zipper header) takes 0.5 to 1.5 inches. Because the center of the bag pillows outward as it fills, add half of your item's thickness to both width and height. Whether you are comparing 3 side seal pouches, custom printed sachets, flat barrier pouches, custom sample packets or flat heat seal bags, we size the template to your exact container.
| Outer size (W × H) | Typical fill weight or item | Common flat pouch applications |
|---|---|---|
| 2.5 × 3.5 in | 2 to 10 ml liquid or 3 to 5 g powder | Cosmetic serum sachet, shampoo sample, 2-capsule pack |
| 3 × 4.5 in | 5 to 15 g (0.2 to 0.5 oz) | Single-serve drink powder, tea bag overwrap, trading cards |
| 3.5 × 5 in | 15 to 28 g (0.5 to 1 oz) | Garden seed packet, gummy sample, single-serve nuts |
| 4 × 6 in | 28 to 57 g (1 to 2 oz) | Single-pot coffee packet, spice rub, travel bath soak |
| 5 × 7 in | 1 folded sheet mask or 2 to 3 oz dry | Facial sheet mask pouch, eye patches, flat chocolate bar |
| 6 × 9 in | 57 to 113 g (2 to 4 oz) | Beef jerky slab, dried fruit slices, flat hardware kit |
Have your inside dimensions ready? Request pricing across up to 3 quantities.
Request a Quote →How do I choose flat pouches?
- Account for pillow bulgeWith no bottom gusset, the front and back sheets bow outward around your product; add half of fill thickness to width and height.
- Choose tear-open vs zipperSkip the zipper on single-use sachets and sheet masks to save height and cost; add a press-to-close zipper on multi-serving jerky.
- Subtract seal margins from usable spaceDeduct 0.5 to 0.75 inches total for left and right side welds, plus 0.5 inches (no zipper) or 1.5 inches (with zipper) at the top.
- Plan how the packet displaysFlat pouches do not stand upright on their own: add a top hang hole for peg hooks or pack them inside a counter display box.
- Match barrier core to formulaUse foil-lined barrier film for liquid serums, alcohol wipes and hygroscopic powders; use clear windows for dry spices and seeds.
- Check open-top vs open-bottom fillingZipper flat pouches arrive open at the top; non-zipper 3-side-seal sachets can arrive open at the top or bottom to suit your sealer.
What are flat pouches made of?
Which finishes can flat pouches have?
Which features and display options pair with custom flat pouches?
Flat pouches specifications
| Spec | Options |
|---|---|
| Pouch styles | 3-side-seal flat pouch, 4-side-seal sachet, resealable zipper flat pouch, window flat pouch |
| Barrier structures | Multi-layer polymer film, foil/metallized or kraft barrier structures matched to your product |
| Printing | Edge-to-edge full color (CMYK) on front and back; Pantone color matching guaranteed |
| Surface finishes | Matte, gloss, soft-touch lamination, spot UV, metallic foil accents |
| Closures & features | Stand-up, flat-bottom or sachet pouches custom made to your closure and display format |
| Size range | Custom outer Width × Height in inches from 2 × 3 in micro sachets to 10 × 12 in flat bags |
| Minimum order | Minimums depend on the product; we confirm yours with your quote |
| Food contact & safety | Food-safe materials on request in a certified partner facility; certificates shared on request |
| Proofs & samples | Free 2D proof and 3D mockup before payment; $50 sample kit or paid sample credited to order |
| Turnaround & shipping | 10-14 business days (rush 4-5 days); free shipping to all 50 US states, worldwide DDP available |
Ready to quote your flat pouches? Compare up to 3 quantities with a free 3D mockup.
Request a Quote →What do brands pack in custom flat pouches?
Whenever a product is consumed in a single serving, naturally flat in shape, or mailed inside slim subscription envelopes and retail display caddies, a custom flat pouch delivers full barrier protection with minimal material bulk. Tell us what you are packing so we match the right seal margin.
Flat pouches design ideas
Example designs with made-up brands. Your packaging is made to your design.
What are the most common custom flat pouch mistakes?
Because a flat pouch has no bottom gusset to absorb depth, overlooking seal borders and pillow bulge can make small sachets too tight to seal. When specifying flat pouches with logo, branded flat pouches, wholesale flat pouches, bulk custom flat pouches and personalized flat pouches, avoid these common production mistakes
- Forgetting to subtract 0.5 to 0.75 inches from outer width for the left and right side heat welds when sizing around a flat item like a sheet mask or card.
- Sizing a flat pouch to exact 2D dimensions without adding pillow-bulge room for 3D powder mounds, capsules or thick jerky strips.
- Adding a press-to-close zipper to a tiny 3.5 inch tall single-serve sachet, leaving less than 2 inches of usable interior height.
- Placing fine ingredient text or lot numbers within 0.375 inches of the outer edges where the heated crimping jaws emboss the border.
- Sending loose flat pouches to grocery or boutique retailers without a top hang hole or a counter display caddy, leaving stores nowhere to stand them.
Chat with a designer now
Share your logo, a sketch or an AI image. We'll rebuild every element cleanly onto your bag dieline and send a 3D mockup, free.
Made your design with AI?
Generated a concept in Google Gemini, ChatGPT, Claude or Midjourney? Send us your AI image: we rebuild every element onto your bag dieline and show you a 3D mockup before you pay, free.Custom printed flat pouches vs blank sachets with labels: how do they compare?
| Blank stock sachets + stickers | Custom flat pouches from CubitPack | |
|---|---|---|
| Packet thickness & profile | Stock pouch with a thick paper sticker that stiffens the packet | Printed directly into the barrier film so sachets stay ultra-thin and flexible |
| Small text legibility | Desktop-printed labels smudge on small 3 × 4 in sachets | Crisp 5-point ingredient and dosing text printed directly on the pouch |
| Exact sachet dimensions | Limited to a few generic sizes | Cut to your exact Width × Height with zero die or plate charges |
| Packing & sealing speed | Requires hand-sticking labels onto hundreds of tiny packets | Arrives fully printed and ready to fill and impulse-seal |
| Color & proofing | Unbranded foil or kraft | Guaranteed Pantone match, free design help, 2D proof and 3D mockup |
Get custom flat pouches sized to your product, with a free 3D mockup before you pay.
Request a Quote →Are flat pouches safe and sustainable?
Food-safe and cosmetic-compatible inner liners
Food-safe inner barrier layers are available on request through certified partner facilities for powders, tea, jerky and supplements. Certificates and lab test reports are shared on request.Wide hermetic side and bottom weld seams
Our 3-side-seal and 4-side-seal packets use 0.25 to 0.375 inch heat-weld borders so single-serve powders, bath salts and wet cosmetic masks stay sealed under parcel compression.Prepress check on tear-notch & seal clearance
Before printing, our prepress team checks your artwork to ensure tear notches, hang holes and heat-seal bands never cut into dosing instructions or barcodes.How do I order custom flat pouches?
Tell us what you need
Size, quantities or AI conceptCompare volume pricing
Dedicated account managerApprove your proof
Digital proof + 3D mockupMade and shipped
Free to all 50 statesWhat affects the cost of custom flat pouches?
The price depends on four things, and every custom quote is free.
Outer width × height
Because flat pouches have no bottom gusset, they use less film than stand-up pouches of the same face sizeTear-open vs resealable zipper
Simple tear-open 3-side-seal sachets cost less per unit than flat pouches fitted with a zipper trackTotal quantity & multi-flavor runs
Sharing one Width × Height across all flavors spreads setup and lowers unit costBarrier film & finishes
Foil cores, kraft paper laminates, soft-touch film and foil stamping affect unit costBuilding a 7-day or 30-day sample kit? Keep all flavor sachets at the exact same Width × Height so they run together on one dieline, and pack them inside a matching custom folding carton or display box. You pay no die or plate charges, get 10% off your first order, and we beat any written US competitor quote. Buyers ordering custom size flat pouches or 3-side-seal flat pouch flat pouches can compare up to three quantities in one quote.
10% off your first order.
Request a Quote →What do I need to send for a quote?
- The product and how many you need
- The inside size, or what goes in it
- A style, or ask us to suggest one
- Your logo or artwork (an AI image is fine)
- Pantone codes, if you have them
- Delivery ZIP code and the date you need it
Can I see a sample first?
Sample kit
Board and finish swatches, sample boxes, labels and bags. Credited to your first order.Digital proof + 3D mockup
See it before you payPrinted sample
Of your own designHow does shipping work?
- Free shipping to all 50 states
- Worldwide with DDP prices: duties and taxes included
- Blind and split shipping
- Damaged in transit? We reprint the damaged units free
Why brands choose CubitPack
Dedicated specialist
One account manager from quote to deliveryPantone guaranteed
Clearly off? We reprintReprint or refund
If we get it wrong, you chooseBBB accredited
A US business you can checkFlat pouches questions
What is the minimum order quantity for custom flat pouches?
Minimums depend on the product and packet size, so we confirm yours with your quote. Trial runs are reviewed case by case, and you can compare up to three quantity tiers in the quote form.
What is the difference between a 3-side-seal flat pouch and a stand up pouch?
A 3-side-seal flat pouch has two flat panels sealed along the sides and bottom with no bottom gusset, so it lies flat or hangs from a peg hook. A stand up pouch adds a W-folded bottom gusset that opens flat so the bag stands upright on a shelf.
What is the difference between a 3-side-seal pouch and a 4-side-seal sachet?
A 3-side-seal pouch is folded from a single sheet of film so one edge is a smooth fold and three edges are heat-welded. A 4-side-seal sachet is made from two separate sheets welded around all four edges for a uniform border.
How do I size a flat pouch when my product has thickness?
Because a flat pouch has no bottom gusset, the front and back sheets bow outward like a pillow around your product. Add at least half of your item's thickness plus 0.75 inches for side seals to the width, and add 1 to 1.5 inches for the top seal to the height.
Can custom flat pouches hold liquids, gels or soaked facial sheet masks?
Yes, when built with a liquid-compatible foil barrier laminate and wide 4-side-seal or 3-side-seal welds. Note liquid, serum, gel or alcohol-wipe contents on your quote so we specify the right inner sealant layer.
Can I add a resealable zipper or hang hole to a flat pouch?
Yes. While single-serve sachets usually use tear notches only, larger 4 × 6 inch, 5 × 7 inch and 6 × 9 inch flat pouches for jerky, gummies, seeds and hardware frequently include a press-to-close zipper and a round or euro hang hole.
How do custom flat pouches arrive for filling and heat sealing?
Standard flat pouches arrive sealed on the sides and bottom with the top mouth open (and the zipper unlocked if included). You drop or funnel your product in through the top and seal the top edge with an impulse or band heat sealer.
Are your custom flat pouches safe for food, tea and dietary supplements?
Yes, food-safe inner barrier liners are available on request. When you note food, beverage, tea or supplement use on your quote, we produce the order in a certified partner facility and share certificates on request.
Can you make a matching counter display box to hold our flat pouches?
Yes. Because flat pouches lie flat unless hung on a peg hook, many brands order a custom retail display box (PDQ tray or pop-top dispenser carton) sized to hold 12, 24 or 30 upright sachets in matching Pantone colors.
How long do custom flat pouches take to produce and ship?
Standard production takes 10 to 14 business days after you approve your 2D digital proof and 3D mockup and complete payment. Rush production in 4 to 5 business days is quoted per order. Standard shipping to all 50 US states is free.
Still have a question? Ask a packaging specialist.
Request a Quote →Flat pouches terms, explained
- 3-side-seal pouch
- Flat bag sealed on three edges (or folded on bottom and welded on sides) with one open end for filling
- 4-side-seal sachet
- Flat packet welded along all four outer margins for uniform borders and liquid or wipe containment
- Pillow bulge
- The natural outward curve of a gusset-free flat pouch when filled with powder, granules or a folded mask
- Tear notch
- Small V-shaped cuts in the left and right side seals that let users rip open a sachet without scissors
- Euro-slot hang hole
- Sombrero-shaped punch hole centered in the top header so flat pouches hang straight on retail hooks
- Seal margin
- The ¼ to ⅜ inch heated weld perimeter around a flat pouch that keeps air and moisture out
More for your supplements packaging
Learn more
Get your flat pouches price
One dedicated account manager prepares pricing across up to 3 quantities.
- Free design & AI-to-print studio + 3D mockup
- No die or plate charges · 4–5 day rush available
- Free shipping to all 50 states
- 10% off your first order
- Reprint or refund if we get it wrong
Every CubitPack service fact on this page comes from our confirmed offers (10-14 business day turnaround, 4-5 day rush, free design help, no die or plate charges, free 50-state shipping and food-safe partner production on request) and was checked by a packaging specialist. Spot something wrong? Tell us and we will fix it. Tell us if something looks wrong.
Sources
What changed
- October 22, 2026: First published.
- October 22, 2026: Updated specifications, terminology, and verified source links.