Gusset or No Gusset: Packaging Considerations for Thick Products

Gusset or No Gusset: Packaging Considerations for Thick Products

What is a Gusset in Packaging?

A gusset is additional material added to the sides or bottom of a bag, pouch or mailer, allowing it to expand and hold more volume. This extra material creates a pleat-like structure that opens up when filled, accommodating thicker or bulkier items that wouldn't fit in a flat bag or mailer.

Packaging Types and Gusset Considerations:

  1. Padded Mailers: Padded mailers cannot be made with a gusset due to their construction. While they offer cushioning for fragile items, they may not be suitable for thicker products that require more space. Adding dimension to the width to fit bulkier items works well for padded mailers and polymailers.
  2. Poly Mailers: Poly mailers typically do not require a gusset because their flexible material allows them to expand as needed. 
  3. Kraft Mailers: Gusseted poly mailers are excellent for kraft mailers that need to hold thicker items. The gusset allows the mailer to expand and accommodate the extra thickness without compromising the integrity of the packaging.
  4. Ocea Bags: Ocea bags, used for shipping clothing and textiles, can also be made with a gusset. This feature provides additional space and flexibility, making them suitable for a wide range of products.
  5. Pouches: Pouches often feature gussets, either on the sides or bottom, to provide extra room for bulky or irregularly shaped items. The gusseted design allows the pouch to stand upright when filled, maximizing shelf appeal.

Why Choose Gusseted Packaging?

  • Increased Capacity: Gusseted packaging offers more room for thicker or bulkier items, allowing you to efficiently pack and ship a wider range of products, especially when it comes to Recycled Kraft paper mailers.
  • Improved Presentation: The expanded shape of gusseted packaging provides a more attractive presentation, especially for retail display or unboxing experiences.
  • Enhanced Versatility: Gusseted packaging can adapt to various product sizes and shapes, offering flexibility and versatility in packaging solutions.
  • Reduced Waste: By choosing packaging that works with thicker items by using gussets, you can minimize the need for excess packaging material and reduce waste in your shipping process.

Whether you're shipping bulky clothing, supplements, or other thick products, the choice between gusseted and non-gusseted packaging can significantly impact your packaging strategy. At EcoPackables, we offer a wide range of sustainable packaging solutions tailored to meet your specific needs. We can guide you in finding the right option to meet your needs while minimizing environmental impact and maximizing efficiency in your supply chain.

Back to News