Flat-Bottom Box Pouches

Boxbaba Flat-Bottom Box Pouches are five-panel, high-barrier flexible packages built for strength, stability and longer shelf life. Made with PET, VMPET, or aluminum foil laminations and food-grade sealants, they protect against oxygen and moisture while supporting nitrogen flushing. Custom sizing, CMYK or PMS printing, matte or specialty finishes and optional valves or zippers are available. With a 100-unit MOQ, 5–9 day production and free USA shipping, they suit coffee, pet food, supplements, ecommerce and wholesale brands.

4.3 Reviews 8 • Excellent

Andrew Diedrich

Greatest P......

My contact at BoxBaba, Marcel, was very tentative and responsive. He gave me all box outlines…

Date of experience:

Dec 2, 2025

Matt Lab

Greatest P......

These guys are legit Top-notch service and high quality products.

Date of experience:

Sep 19, 2024

Myralyn

Greatest P......

We recently purchased box sleeves and we couldn’t be happier with both the product and the service we received…

Date of experience:

Feb 15, 2025

Hannah Ahmed

Greatest P......

For our recent product launch, we needed packaging that would really make an impression. The custom boxes from BoxBaba…

Date of experience:

Apr 26, 2025

Matteo

Greatest P......

I’ve been very pleased with my experience with BoxBaba and Cristina from Customer Service to communicate our…

Date of experience:

Apr 29, 2025

Carol Scott

Greatest P......

Absolutely phenomenal service and product! David Wells far exceeded expectations to deliver high-quality custom…

Date of experience:

Jul 9, 2025

Doug C

Greatest P......

Marcel and David are very responsive, thorough and a pleasure to work with. I appreciated their efforts to customize…

Date of experience:

Jul 15, 2025

Jess B

Greatest P......

I’ve loved working with BoxBaba. Their representatives have been extremely responsive and their prices are very…

Date of experience:

Sep 10, 2025

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Order any quantity, enjoy a wholesale price, pay no extra for die plates.

Product Specification

Specification	Standard Range / Details
Thickness	110–180+ microns
Seal Type	Heat seal, zipper seal
Closure Options	Zipper, child-resistant zipper, degassing valve
Valve Type	One-way degassing (coffee grade)
Finishes	Matte, gloss, soft-touch, metallic
Printing	CMYK, Pantone
Compliance	FDA food-contact compliant materials available
Testing	ASTM seal strength testing available
MOQ	Starts at 100 units (flexible)
Production Timeline	5–9 business days
Shipping	Free USA shipping

Shipping

We have Air, Ground, and Sea shipping options available depending on the manufacturing origin and destination. Our Trusted partners are DHL. FEDEX & UPS.

Material

We comprehend that finding the ideal custom packaging Material to meet your requirements can be quite challenging. To make it easier for you, we've assembled a collection of material options, carefully chosen based on their capabilities like SBS Cardstock (16 to 24 pt), Eco-Friendly Kraft, Corrugated (E, B, AB etc. flutes)

Ads-Ons & Finishing

Explore our finest collection of premium finishes to give a magnificent look and feel to your custom packaging while increasing its protectiveness. You can Choose Foiling, Holographic Foiling, Aqueous Coating, Embossing/Debossing, Gloss/Matte Lamination, Soft Touch, Spot UV/Spot Gloss

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Engineered Five-Panel Stability for Heavy Fills

The flat rectangular base and reinforced side seals spread product weight evenly. This reduces bottom seal stress and improves pallet stacking. The structure holds its shape during automated filling, transport and retail display, delivering consistent performance in demanding distribution environments.

High-Barrier Flat-Bottom Pouches for Stable Retail Display

Flat-Bottom Box Pouches are strong, five-panel flexible packages built for stability and protection. They combine the solid feel of a box with the efficiency of flexible film. Made from PET, VMPET, aluminum foil and food-grade PE, they block oxygen and moisture effectively. The reinforced structure supports heavier fills and reduces seal stress. Ideal for coffee, supplements, pet food, specialty snacks and performance powders.

What Are Flat-Bottom Box Pouches?

Flat-bottom (block bottom) pouches are five-panel flexible packaging formats featuring:

A flat rectangular base
Four side panels
Reinforced vertical seals
Box-style geometry for upright display

This structure distributes product weight across multiple panels instead of relying on a single bottom seal. This significantly reduces bottom burst risk and improves load-bearing capacity during transport. Commonly used for:

Premium Coffee Bags
Pet nutrition and Pet Treat Mylar Pouches
Protein powders
Dried Fruit Packaging Bags
Nutraceuticals and supplements

Why Businesses Choose Flat-Bottom Box Pouches

Structural Load Distribution Engineering

Five-panel weight distribution lowers seal stress and improves durability during pallet stacking, freight movement and automated filling.

High-Barrier Performance

Engineered laminations deliver controlled:

Oxygen Transmission Rate (OTR)
Moisture Vapor Transmission Rate (MVTR)
UV and aroma protection

Compatible with nitrogen flushing and Modified Atmosphere Packaging (MAP).

Premium Shelf Psychology

Box-like geometry signals rigidity and value, increasing perceived product quality while retaining flexible packaging cost advantages.

Automation-Ready

Maintains shape consistency for vertical and high-speed filling systems.

Material Structure & Barrier Engineering

Outer Layer (PET or MOPP)

Provides print clarity, abrasion resistance and branding impact.

Middle Barrier Layer (VMPET or Aluminum Foil)

Controls oxygen, moisture, aroma migration and light exposure.

Inner Sealant Layer (PE or CPP)

Ensures seal integrity, food safety and puncture resistance. Barrier selection is calibrated based on:

Product water activity (aw)
Shelf-life targets
Storage conditions
Export requirements

For ultra-sensitive applications, explore Smell Proof Mylar or Vacuum Sealed Mylar Bags structures.

Flat-Bottom vs Other Pouch Formats

Feature	Flat-Bottom	Stand-Up	Side Gusset
Stability	Excellent	Moderate	High
Shelf Blocking	Premium	Standard	Industrial
Load Distribution	5 panels	Single bottom seal	2 side panels
Ideal For	Coffee, pet food, supplements	Snacks	Bulk goods
Automation	Excellent	Good	Excellent

Flat-bottom designs provide stronger premium positioning than a standard Flat Mylar Bag and improved retail presence compared to many Side Gusset Pouch formats.

Customization & Functional Options

Printing & Branding

Full CMYK and Pantone
Matte, gloss, soft-touch
Spot UV
Foil stamping
Embossing/debossing
Transparent window panels

Functional Add-Ons

Resealable zipper (see Resalable Mylar Bags)
Child-resistant closure (compatible with Child Resistant Mylar Bags)
Degassing valve for coffee
Tear notch
Hang hole

Compliance & Quality Control

For food, supplement and regulated applications:

FDA food-contact compliant materials available
Documentation provided upon request
Seal integrity testing
Load-bearing validation
Thickness verification
Print quality inspection
Optional shelf-life validation testing

Designed to meet performance expectations of modern Food Mylar Bags and specialty applications including Custom Beef Jerky Packaging Bags.

Logistics & Operational Efficiency

Delivered flat to reduce warehouse footprint
Reduced freight cost vs rigid formats
Free USA shipping
Free samples (credited on first bulk order)
Flexible MOQ starting at 100 units
Scalable for ecommerce and wholesale

Why Choose BoxBaba for Flat-Bottom Box Pouches

Engineered structural support for heavy fills
Barrier calibration based on product sensitivity
FDA-compliant material options
ASTM testing support
5–9 business day production timeline
Flexible MOQ starting at 100 units
Free USA shipping
Free sample reimbursement on bulk orders

BoxBaba supports ecommerce brands, wholesalers, coffee roasters, supplement companies and pet nutrition manufacturers with scalable, compliance-ready packaging solutions.

Order Custom Flat-Bottom Box Pouches

If you need stable, high-barrier packaging engineered for durability, shelf impact and automated filling compatibility, our team will design a structure aligned with your product weight, shelf-life target and branding goals. Call +1 305 574 4357 Email: sales@boxbaba.com Request a custom quote today.

Frequently Asked Questions

Find all the urgent questions you may have.

Are flat-bottom pouches better than stand-up pouches?

For heavier fills and premium shelf display, yes. They provide stronger structural support and improved load distribution.

Can flat-bottom pouches support nitrogen flushing?

Yes. Compatible with nitrogen flushing and Modified Atmosphere Packaging (MAP).

What OTR is recommended for coffee?

Ultra-low OTR structures (<50 cc/m²/day) are typically recommended, combined with a one-way degassing valve.

Are these suitable for pet food and heavier products?

Yes. Reinforced vertical seals and five-panel distribution reduce bottom burst risk.

Do you offer child-resistant options?

Yes. Child-resistant zipper configurations are available for regulated categories.

What thickness is recommended for 5 lb pet food?

Typically 160+ microns depending on product density and distribution channel.

Flat-Bottom Box Pouches

4.3

Reviews 8 • Excellent

Andrew Diedrich

Date of experience:

Dec 2, 2025

Matt Lab

Date of experience:

Sep 19, 2024

Myralyn

Date of experience:

Feb 15, 2025

Hannah Ahmed

Date of experience:

Apr 26, 2025

Matteo

Date of experience:

Apr 29, 2025

Carol Scott

Date of experience:

Jul 9, 2025

Doug C

Date of experience:

Jul 15, 2025

Jess B

Date of experience:

Sep 10, 2025