Dieline & Size Specification for Stand-Up Pouches
A well-developed dieline is essential for achieving accurate pouch dimensions, stable standing performance, reliable sealing, and smooth filling operations. The dieline should be developed according to the pouch structure, material thickness, closure type, filling volume, and production equipment.
Dieline Structure
A stand-up pouch dieline normally defines the overall width, height, bottom gusset, sealing areas, zipper or spout position, and corner geometry. It should clearly distinguish between the finished pouch dimensions and the film dimensions required for manufacturing.
Sealing allowances must be incorporated into the dieline so that the final internal capacity meets the specified requirements. Cutting lines, fold lines, and sealing boundaries should be clearly identified to avoid production errors.
Width and Height
Pouch width and height should be selected according to product volume, density, filling level, and shelf presentation requirements. The pouch should provide sufficient headspace for sealing without excessive empty space.
For products with irregular shapes or large particles, additional space may be required to prevent excessive stress on the seals and pouch walls.
Bottom Gusset Dimensions
The bottom gusset is responsible for creating the supporting base. Gusset depth must be properly matched with pouch width and product weight.
An insufficient gusset can result in poor standing stability, while an excessively deep gusset may increase material consumption and create forming difficulties. Prototype testing with the actual product is recommended before finalizing the dieline.
Closure Position
For zipper pouches, the zipper location should provide sufficient opening space while maintaining a reliable upper seal. For spouted designs, the spout diameter, flange dimensions, position, and sealing area should be incorporated into the dieline.
Component placement must also be compatible with automated filling and sealing equipment.
Tolerances and Production Control
Critical dimensions should have defined tolerances for pouch width, height, gusset depth, seal width, zipper position, and spout position. Consistent tolerances help maintain production stability and ensure compatibility with filling machinery.
The final dieline should be verified against actual production samples. Dimensional inspection should be performed after forming and sealing because material shrinkage and processing conditions may affect the finished dimensions.
Design Verification
Before mass production, conduct prototype evaluation, filled-pouch standing tests, dimensional checks, seal testing, and equipment trials. A validated dieline reduces material waste, minimizes conversion problems, and improves consistency between production batches.
References
ISO 9001 – Quality Management Systems
ASTM F88 – Standard Test Method for Seal Strength of Flexible Barrier Materials
ASTM F2096 – Standard Test Method for Detecting Gross Leaks in Packaging by Internal Pressurization
ASTM D4169 – Standard Practice for Performance Testing of Shipping Containers and Systems
ISO 11607 – Packaging for Terminally Sterilized Medical Devices
