You have already picked the format — a stand-up pouch (doypack) beats a flat-bottom bag or rigid jar for your product, shelf, and filling line. The harder step is specifying the pouch itself: the film structure, size, closure, and barrier that keep the product fresh and your line running. This guide walks each decision in the order a buyer actually faces it, and ends with the exact inputs a factory needs to quote you accurately.
What a stand-up pouch is — and why "doypack" means the same thing
A stand-up pouch is a flexible bag with a bottom gusset that unfolds when filled so the pack stands upright on a shelf. "Doypack" is the original trade name (from French inventor Louis Doyen, 1963); today the two words describe the same bottom-gusseted format. The gusset — not a rigid base — gives standing stability, so its seal type matters as much as the film. Browse our stand-up pouch range for the in-stock structures we run.
Material structure: three layers, one job each
Almost every stand-up pouch is a multi-layer laminate where each layer does one job: an outer layer (PET/BOPP, or kraft) carries print and stiffness; a barrier layer (aluminium foil, metallised PET, or EVOH) blocks oxygen, moisture, and light; an inner layer (PE/CPP) provides the heat seal and food-contact safety. The barrier layer is the single most important choice.
| Structure | Barrier | Best for | Key limitation |
|---|---|---|---|
| PET / PE | Low–medium | Dry goods, short shelf life | Transparent, modest barrier |
| PET / VMPET / PE | Medium | Snacks, nuts, dry food | Not curbside-recyclable |
| PET / AL / PE | High | Coffee, spices, long life | Not microwave-safe |
| Kraft / PE | Low–medium | Eco-branded dry goods | Paper outer only |
| NY / PE | Medium + puncture | Frozen, heavy, sharp | No high barrier |
| PET / AL / NY / PE | High + puncture | Liquids, heavy/abrasive | Four-layer, costlier |
Limitation to plan around: foil gives the longest shelf life but cannot go in a microwave and is not curbside-recyclable; metallised and transparent films are lighter on barrier but show the product. If recyclability is a stated brand goal, ask for a mono-material PE structure — it trades some barrier for drop-off recyclability. The foil-versus-metallised trade-off is covered in detail in our foil-layer guide.
Sizing and the dieline
Size is set by fill weight and product density, not looks: a 2 lb bag of low-density granola needs more volume than a 2 lb bag of dense coffee. Give your supplier the target fill weight and they will recommend width × height × gusset depth. Three common bottom seals: Doyen (round) — clean retail look; K-seal — shifts stress off side seams, better for heavy fills; Plow bottom — one-piece film, good for powders. Your supplier issues a dieline (flat cutting template with dimensions, seal points, feature placement); keep key text and logos out of the gusset fold, which distorts in production.
Closures and functional features
Pick by how the user opens and reseals: resealable zipper (snacks/coffee/pet food); tear notch (low-cost easy-open); one-way degassing valve (fresh-roasted coffee, vents CO₂, blocks oxygen); spout + cap (liquids/sauces — inner layer must suit the product: PE for aqueous/oil, CPP for hot-fill); clear window (shelf visibility); hang hole / rounded corner (retail display). Spout seals follow the same logic as our lidding film applications.
Barrier and shelf life
Oxygen and moisture spoil most dry products; barrier is measured as OTR (oxygen transmission rate) and WVTR (water-vapour transmission rate), lower is better. Rule of thumb: coffee, spices, long life → foil (PET/AL/PE), often with a valve, commonly 12–24 months; snacks/nuts → metallised (PET/VMPET/PE), typically 6–12 months; eco/short-life dry goods → kraft or mono-PE, shorter windows. For retort and hot-fill products, foil structures are proven at 121 °C — see our retort pouch guide. Request the supplier's OTR/WVTR test data for the exact structure — typical published values vary with layer thickness and should be verified, not assumed.
Printing and finishes
Rotogravure — cylinder-based, lowest per-unit cost at volume, sharp colour; our standard for runs from 10,000 pieces per design. Digital — no plates, faster setup, better for small trial batches at higher per-unit cost. Finishes: matte, gloss, soft-touch, metallic, spot UV. Send artwork at 300 DPI with vector logos; CMYK for print.
Applications at a glance
| Product | Recommended structure | Key feature |
|---|---|---|
| Coffee (roasted) | PET/AL/PE | Degassing valve |
| Snacks / nuts | PET/VMPET/PE | Zipper + window |
| Pet food (1–5 kg) | PET/AL/PE or NY/PE | Reinforced gusset |
| Protein / powder | PET/AL/PE | Zipper, low WVTR |
| Spices | PET/AL/PE | Aroma barrier |
| Cosmetics / non-food | PET/PE or kraft | Matte finish |
| Liquids / sauces | PET/AL/NY/PE + spout | CPP or PE inner |
See real examples we have produced: a dried mango snack pouch with window, a protein powder resealable pouch, a mixed nuts pouch with window, a chicken dog food pouch, and a herbal tea loose-leaf pouch.
How to choose — and when not to
Start from four inputs: product category, fill weight, target shelf life, distribution channel. A factory with category experience can reverse-engineer the film structure from those alone — you do not need to know the OTR target. Not recommended for a stand-up pouch when the product needs rigid protection or precise cavities (use a box/tray), when barrier or food-contact rules are still undefined, or when the fill method and seal area have not been checked against your packing line.
What to send for a quotation
To get an accurate quote instead of a vague range, send: (1) product type and whether it contacts food directly; (2) fill weight and target volume; (3) required shelf life and distribution (ambient / frozen / export); (4) preferred size or W×H×gusset, or a sample to match; (5) closure (zipper / valve / spout / window / hang hole); (6) film structure or barrier target (OTR/WVTR if known); (7) print colours, finish, SKU count; (8) quantity range and desired lead time; (9) destination country and any compliance documentation needed.
At Gerun Pack, custom stand-up pouches start at 10,000 pieces per design, with typical lead time 15–25 days after artwork confirmation. We run an ISO 9001 quality system and validate food-contact films with FDA-accredited laboratory test reports; request the compliance file for your market when you enquire.
Frequently asked questions
What is the difference between a stand-up pouch and a doypack?
None — "doypack" is the original brand name; "stand-up pouch" is the generic term for the same bottom-gusseted format.
Are stand-up pouches food safe?
Yes, when made with food-grade films, inks, and adhesives. Ask your supplier for the food-contact compliance document your market requires (e.g. FDA 21 CFR for the US, EU 10/2011 for Europe).
Can stand-up pouches go in the microwave?
Not aluminium-foil structures — foil blocks microwaves and can arc. Transparent or metallised films without foil may be microwaveable only if the supplier confirms the specific structure.
What is the minimum order for custom printed stand-up pouches?
At Gerun Pack, 10,000 pieces per design for gravure. Digital short runs are possible for trials at a higher per-unit cost — share your volume and we will advise the economical route.
Can stand-up pouches be recycled?
Standard foil or metallised laminates are not curbside-recyclable because they combine different materials. Mono-material PE structures are recyclable through store drop-off in many regions. Tell your supplier your sustainability requirement and they will match the structure.
How long does a stand-up pouch keep product fresh?
It depends on barrier structure and product. Foil laminates commonly deliver 12–24 months for dry foods; metallised 6–12 months; kraft or mono-PE shorter. Confirm with the supplier's test data for your exact spec.
Which structure should I use for coffee?
A high-barrier foil laminate (PET/AL/PE) with a one-way degassing valve; request the supplier's OTR/WVTR data for the proposed structure.
Can stand-up pouches hold liquids?
Yes — spouted stand-up pouches (screw or push-pull cap) are standard for juices, sauces, and detergents; the inner seal layer must suit the liquid (PE aqueous/oil, CPP hot-fill).
Next steps
Browse our stand-up pouch range for in-stock structures, compare stand-up vs flat-bottom if the format is still open, read our foil-layer guide to decide if you need foil at all, or request a quote with the checklist above.
