Rated 4.6 out of 5 based on 96 reviews on Trustpilot
Rated 4.6 out of 5 based on 96 reviews on Trustpilot
At Shop Rigid Boxes, we offer side gusset pouches suitable for high-volume goods like coffee, snacks, pet food, and powders. These pouches are retail and custom made hence come in different sizes and shapes so that you can get the right product pouch. They offer customized printing, you can have your logo or unique colorful prints that give customers a glimpse at them. Our pouches are made of environmentally friendly material to support companies that are interested in a green policy but do not want to sacrifice quality. Its strong structure makes it suitable to protect the product during transportation. Pouches preformed, pre-made, ready to use. Order your pouches today and pack with ease.
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| Box style | Side Gusset Pouches |
|---|---|
| Dimensions | All custom sizes and shapes |
| Minimum quantity | 100 boxes |
| Board | Greyboard 1.5mm – 3mm |
| Wrap stock | 128–157gsm art paper, kraft, or textured |
| Closure | Two concealed neodymium magnets |
| Format | Assembled or collapsible |
| Printing | Offset and digital, CMYK + spot colour |
| Lamination | Matte, gloss, or soft touch |
| Add-on finishes | Spot UV, foil, embossing, debossing |
| Inserts | Foam, EVA, pulp, card — velvet or silk lined |
| Proof | Free digital proof, sample on request |
| Turnaround | 12–15 business days after approval |
| Shipping | Flat rate, tracked |
Offset Printing
Digital Printing
Pantone Colors
Soft Touch Lamination
Spot Gloss UV
Hot Foil Printing
Blind Embossing
Window Patching
White Kraft
Natural Brown Kraft
Textured Paper
Grey Chipboard
Side gussets pouches are considered flexible packaging known by folds or gussets on both vertical sides of the pouches. Moreover, the pleats allow them to expand outward, which increases their internal volume while maintaining a small footprint when empty. Furthermore, these are the standard choices of packaging for tea, coffee & pet food packaging. The functions of side gusset pouches are as follows;
Custom side gusset pouches are the top choice for bulky and dense products due to their unique design. Plus, they offer a large capacity, durability & cost efficiency. Hence, the top-notch benefits of these are as follows;
Common applications of custom side gusset pouches are versatile in their uses. Mainly used for bulky or dense products. However, the common applications of pouches are as follows;
Widely used to pack tea and coffee. Moreover, it has one side fold to fit your bulky beans. Plus, it keeps your morning brew fresh & flavorful, such as coffee and loose-leaf tea. So, these types of custom mylar bags are best to pack coffee beans, tea leaves, and powdered supplements. Provides excellent protection from moisture, light, and oxygen.
Our custom pouches have strong extra layers, which is why they handle heavy kibble without tearing. The flat bottom side of it helps the stand pouches upright without tipping over. You can also opt for sachet packets, which are small, sealed bags. Commonly, these are rectangular, flat, or square in shape.
These pouches are also suitable for freezing items. They won’t get hard or crack at freezing temperatures. They are best to pack frozen items such as vegetables, fruits, seafood, and meat. Our lay flat pouches, also known as flat bags or pillow pouches, provide freezer burn protection, air-tight meals, and durable materials.
These are highly suitable for the packaging needs of the nuts or pretzels. Its wide opening makes it easy for consumers to reach inside the packaging. Plus, preformed pouches are commonly considered a top material for the packaging of nuts and pretzels. used to pack food and beverages, pharmaceuticals, and industrial chemicals. It maintains the freshness and extends shelf life.
Plus, you can also avail spouted pouches for mayonnaise, ketchup, and juice items.
Side gusset pouches are an eco-friendly packaging solution because they use less plastic than heavy jars & boxes. Since they are lightweight and can be folded flat. Moreover, it cuts down pollution & saves pollution, and the second reason for its sustainability is that these are made from special materials that don’t harm the planet. They save space, fewer resources & create less trash.
Tip: “Use packaging materials created from post-consumer waste (PCW) to decrease demand for raw resources.”
Custom sizes of pouches are of different ranges; the measurements are defined by three things: width, height, and depth (WxHxG). However, they can be tailored, but the general categories in which they fall are small, medium, or large, depending on their use.
Furthermore, the table below is given for sizes; it covers all the details.
| Sizes category | packaging capacity | Approximate dimensions | Common uses |
| Small | 25g to 250 g | 3.1’’x5.1’’x2’’ | For tea, spices, and trial samples |
| Medium | 500g to 1 kg | 3.3’’x14.4’’x2.4’’ | 1Lb coffee bags, nuts, and granules |
| Large | 2kg to 5 kg | 8.3’’x20’’x4.3’’ | Suitable for protein powder, rice, and snacks |
| Extra large | 10 kg to 20 kg | 15’’x21.6’’x5.9’’ | Ideal for pet food and birdseed. |
Remember, when choosing a custom size, always add some extra height, 20 to 30 % for heat seal and any air trapped inside the bag. Moreover, these side gusset bags wholesale reduce the shipping costs because they are lightweight & use less raw material, such as rigid paperboard. That is why they are the most affordable packaging solution.
Design methods of these custom pouches involve different methods. They offer a high-capacity, expandable design that provides a premium look for coffee, snacks, and pet food. Furthermore, these versatile bags have a vertical structure & enough surface area that makes them ideal for eye-catching branding & shelf stability.
Plus, the methods used in the custom gusset pouches are as follows;
Flexo graphic printing, also known as flexo. They use flexible polymer plates wrapped around the rotating cylinder to transfer ink to the product. Moreover, they are best for fast production speed and are more affordable in price than the rotogravure method.
Screen printing involves the application of ink through a mesh screen. Furthermore, it is frequently used for applications where a bold, tactile, or textured finish is required.
Hot stamping or foil transfer, it uses heat and pressure to apply metallic or matte foils. Moreover, it is a popular choice for luxury packaging & adds a premium feel with gold & silver designs.
Steps involved in the manufacturing of the side gusset bags include making a custom design onto rolls of film. Then, it is laminated & folded inward to create gussets & a heat-seal. Moreover, the manufacturing process of the custom gusset pouches is as follows;
The first step involves deciding on the artwork for these pouches. Commonly, manufacturers provide 2D digital mock-ups and 3D mock-ups to verify graphics, additional colors fidelity, and placement on all five panels.
The selection of the material depends upon the product’s sensitivity to moisture, oxygen, and air. Furthermore, the three layers add to block oxygen and moisture.
Printing is very important, whether it is any kind of packaging. Moreover, two types of printing, in the manufacturing process, are written as follows:
Lamination is done when multiple film layers are bonded together using glue to create a single, highly durable sheet. It gives it a shiny white appearance.
The fourth step is the most important, as it covers most of the manufacturing process, which involves the formation of the gusset.
Shop Rigid Boxes is a trusted partner for the best quality side gusset pouches. They combine strength, style, and their usefulness. Made from sturdy pouches for strong and durable packaging. Our gusset bags not only protect the products but also enhance presentation. Moreover, we offer on-time delivery, prototypes, and quick turnaround times.
The list of services we provide is as follows;
100 boxes. Per-box pricing drops at 500, 1,000, and 5,000 units, so ask for tiered pricing if you expect to reorder.
12–15 business days from approved proof to dispatch. Rush production is available on request for an additional charge.
Yes. Our design team prepares dielines, sets up your artwork, and produces the proof at no cost, whatever the order size.
very order includes a free digital proof. Physical samples of your exact box can be produced on request before the full run.
Credit and debit cards, PayPal, and bank transfer. Larger runs can be split into a deposit and a balance on dispatch.
Boards are FSC-certified, and inks, coatings, and adhesives meet food-contact standards where the box needs it.