Custom High Barrier Flat Bottom Bag For Tea Bag Packaging

What this pack is

This is a flat bottom bag built for dry goods that lose quality when light and moisture get in. The wall is a three-part laminate: a matte oil finish on the outside, a pure aluminium layer in the middle, and a PE sealant layer on the inside. At 140 micron, the film is stiff enough to hold its shape after filling and heavy enough to survive normal distribution without creasing into the product. The matte oil outer layer takes print well and resists scuffing on the shelf. The aluminium core is the barrier. It blocks light, which protects aroma compounds in tea and coffee, and it slows moisture vapour transmission, which keeps crisp products crisp. The PE inner layer is the heat-seal surface that closes the bag on standard filling equipment.

Sizes are customizable, so the bag can be built around your fill weight rather than the other way round. The structure can also be changed if a different barrier or a recyclable option is needed. The flat bottom format gives you a rectangular footprint and a clean front panel, which is useful when you want the pack to sit square on a shelf or in a display carton.

Features that matter on the line and on the shelf

The base is self-supporting. Once filled, the bag stands on its own without a outer carton or a shelf-ready tray. That saves space in storage and on the display, and it keeps the front panel facing the shopper. The flat bottom also means the bag does not tip when it is part-filled or when a customer picks it up and puts it back.

A tear notch is placed in the seal area so the pack opens without scissors. The notch is a small mechanical cut, not a zip, so it is a single-use opening. If you need reclosability, a zipper can be added. A one-way degassing valve is available for roasted coffee, and a spout and cap can be fitted for liquid or semi-liquid products. A window, carry handle or hang hole can also be specified. Print is available in rotogravure up to 10 colours, digital or flexographic, and the matte oil surface holds fine detail and strong colour without a glossy glare.

Where it is used

The format suits tea in leaf and bag form, ground and whole bean coffee, and dry snacks. Pet food, contract manufacturing runs and other dry goods that need a light and moisture barrier also fit. Typical fill sizes run from small retail units up to larger bulk packs, depending on the dimensions you set. The flat bottom shape is often chosen when the pack has to stand on a shelf or in a club-store display without extra support.

Filling, sealing and the material trade-off

The bag runs on standard vertical or horizontal filling lines with a heat-seal jaw. The PE inner layer seals at normal temperatures, and the flat bottom is formed before filling. Because the laminate contains aluminium, the bag is not see-through and not recyclable in paper or mono-material streams. That is the trade-off: aluminium gives a strong light and moisture barrier, but it rules out recyclability. If recyclability is a requirement, a mono-material PE or PP structure or a compostable PLA/PBS option can be discussed, but the barrier performance will differ and should be tested against your shelf-life target.

Minimum order quantities start at 100 pieces for pouches with digital printing, or 10,000 pieces with rotogravure. Film starts at 10 kg for digital and 200 kg for rotogravure. Digital runs take 10-15 working days after artwork approval; rotogravure takes 20-25 working days. Free stock pouch samples are available, and you pay courier only. Certifications belong to the manufacturing partner, not to Clover Packaging.