How to Design a Custom Poly Bag, Step by Step

1. Measure the product. Length, width, depth, and weight. Note sharp corners and threads that puncture film.
2. Watch how the bag gets filled. Hand packing works with flat or zipper bags. Automatic baggers need bags on a roll or wicketed bags (bags stacked on a wire for fast loading).
3. Size the bag. A starting point for a flat bag:
   • Bag width = product width + product depth + 1/2 inch
   • Bag length = product length + product depth + 1 inch, plus room for the closure
4. Choose the style. Flat, gusseted (folded sides for boxy products), re-closable zipper, header bag with a hang hole, or bags on a roll.
5. Choose the closure. Open top for heat sealing, zipper, adhesive tape, or a perforated tear-off.
6. Spec the film. Thickness, resin, and additives. Post 7 covers film specs.
7. Add print if needed. Part numbers, lot code areas, logos, and warning statements. Several states require suffocation warnings on bags above certain sizes.
8. Sample and test. Run samples on your bagger or packing table for a full shift. Check seal strength and puncture resistance before you order.

• How many bags per week, and how do you fill them?
• Does the product ship inside a box, or does the bag ship alone?
• Any static, rust, food contact, or clean room requirements?

If a supplier quotes a bag without asking these questions, ask why.

Time a packer filling 100 bags in today’s size. Repeat with a sample bag sized to the product. Multiply the seconds saved per bag by weekly bag volume and hourly wage.

Send us a product sample and your weekly volume. We will size the bag and match the style to your line.

S&S Incorporated · Packaging made easy since 1965 21300 St. Clair Avenue, Cleveland, OH 44117 216-383-1880 · info@sspkg.com · www.sspackaging.com Monday–Friday, 7:00 AM–3:30 PM