How to custom coffee bags？

As a flexible packaging manufacturer working daily with coffee roasters and importers, I am often asked: how to custom coffee bags¹ from start to finish with real production details?

To custom coffee bags¹ you start by confirming artwork and printing method², then choose bag style³ and materials⁴, decide valve and zipper options, confirm quantity⁵ and technology, understand costs⁶ like plate fees⁷, and manage common production risks⁸.

This guide explains each step based on my 15 years of real experience. I will share insights that help you plan custom coffee bags¹ confidently and avoid common mistakes.

How about the steps to custom coffee bags¹?

Many buyers know they need custom bags, but few know the right sequence of decisions that affects cost and quality.

The essential steps are: confirm custom printing or stock bag embossing, choose bag type and materials⁴ for shelf life⁹, decide quantity⁵ and printing technology¹⁰, add valve or finishing options if needed, and review timeline, cost and risks.

Step 1 — Confirm Custom Print or Use Stock Bags

The very first question I ask buyers is whether they want fully custom printed bags or would prefer using our stock bags with a special finish like foil stamping¹¹. This decision affects cost, artwork requirements, and timeline.

We have some universal stock bags in inventory. On these stock bags we can apply hot foil stamping¹¹. For stock bags with hot stamping, we can usually do up to 1–2 colors. If two colors are chosen, the colors cannot overlap.

Using stock bags with hot stamping is often a great choice for small batches because you avoid the cost of full custom printing. Many buyers are surprised that this option can still deliver a premium look and feel for retail.

Step 2 — Confirm Bag Type and Features

After printing method², the next step is to choose the bag type and functional features. Coffee bags are not one-size-fits-all; type influences shelf presence, customer experience, and production complexity.

If products will be displayed on retail shelves, I generally recommend either stand-up pouches or eight-side seal bags. Stand-up pouches are classic and universally accepted. Eight-side seal bags are newer and give a premium look.

For closures, choose inner zippers or easy-tear zippers. Inner zippers are standard. Easy-tear zippers cost more but feel more premium for customers.

Step 3 — Confirm Material Based on Shelf Life

Material determines how well coffee stays fresh. This is a key decision.

For shelf life⁹ over 12 months, I recommend a pure aluminum middle layer. It gives the highest barrier protection.

For 6–12 months, metallized PET¹² is usually enough. Based on our experience, metallized middle layer is the most used structure among our clients due to its balance between cost and protection.

If you're targeting a luxury market, coffee tins are also an option.

Step 4 — Determine Quantity and Printing Technology

Quantity affects printing method² and cost.

Two options:
A. If quantity⁵ is ≤5,000 pcs, we use digital printing¹³ with no plate fee.
B. If quantity⁵ is >5,000 pcs, we use gravure printing¹⁴ with plate fee.

The plate fee is charged once per design and size, and not charged again unless you change them.

Digital and gravure have very little difference visually.
Digital = good for small runs.
Gravure = good for mass production.

Step 5 — Confirm Valve and Finishing Options

If your product is whole beans, add a one-way valve¹⁵. Beans release gas. Without a valve, the bag will puff or break seals.

If it’s ground coffee, the valve is optional. Many brands skip it to save cost.

For a more premium feel, add spot UV or foil stamping¹¹. These attract consumer attention.

Step 6 — Pricing and Confirmation

After all specs are confirmed, we provide a clear quote with itemized costs⁶. We make sure buyers understand what affects the price and how to optimize it.

Pin valve or not on the coffee bags?

Choosing whether to add a valve is a key decision that affects product performance.

For whole coffee beans we strongly recommend a one-way degassing valve to avoid gas build-up and maintain bag shape. For ground coffee the valve is optional but still helpful for maintaining aroma and freshness.

Why Beans Need a Valve

Roasted beans release CO₂. Without a valve, this gas builds up and causes:

• Bag puffing
• Artwork distortion
• Weakening of seals

A one-way valve¹⁵ allows gas to escape while blocking oxygen entry.

Ground Coffee and Valve Use

Ground coffee releases less gas. Some brands skip the valve. But if freshness and aroma are priorities, the valve is still helpful.

Valve Types and Placement

Highly repurchased bag types and bag sizes for coffee bags?

Choosing the right type and size helps brands increase repeat orders and retail success.

Stand-up pouches and flat bottom bags are the most repurchased. Popular sizes are 250g, 500g, 1kg and sometimes 2kg for larger buyers. These sizes match common consumer and wholesale needs.

Most Popular Bag Types

Most Common Sizes

• 250g — Ideal for samplers or single-serve use
• 500g — Common in cafes and retail shelves
• 1kg — Bulk option for loyal buyers or refill packs
• 2kg — Used for wholesale and foodservice customers

For small-batch coffee bag procurement, is there a minimum order quantity⁵?

Many small roasters ask if they need to hit a minimum order quantity⁵ to get started.

Generally we don’t have a strict MOQ, but orders become more economical when quantity⁵ is at least 5,000 pcs. We can still offer smaller runs using digital printing¹³ with reasonable pricing.

For orders under 5,000 pcs, digital printing¹³ avoids the plate fee and shortens setup time. But price per unit is higher.

For best price-performance, aim for 5,000 pcs. Still, we support small brands and can help them start small.

Can coffee bag be customized with metallized bag, UV or foil stamping¹¹?

Finish options can make your coffee bag stand out on the shelf.

Yes, coffee bags can be customized with metallized film, spot UV and foil stamping¹¹. These finishes enhance barrier performance and visual appeal to attract customers.

Common Premium Finishes

These finishes are often combined with matte or kraft textures for visual contrast.

How long is the custom coffee bag production lead time¹⁶?

Delivery time is key for aligning packaging with your product launch.

Typical production lead time¹⁶ is 10–15 days after artwork approval and deposit. For urgent orders we coordinate and can complete in 7–10 days to meet tight schedules.

Our factory has:

• 1 x 10-color printing machine
• 3 x lamination machines
• 2 x eight-side bag machines
• 5+ standard bag machines

This capacity allows flexible planning. For urgent orders, we can prioritize production.

What is the coffee bag production process?

Many buyers don’t know how bags are actually made, and that affects planning.

The production process includes plate making, printing, lamination, lamination curing, bag making, quality testing¹⁷, counting, and packing. Each step has checks to guarantee barrier, strength, and consistency.

Production Workflow

1. Plate making — Engraving of copper plates according to the design draft.
2. Printing — Apply artwork using digital or gravure
3. Lamination — Combine layers for barrier and strength
4. Lamination curing — Enough lamination curing time to avoid bag delamination, eliminate solvent residue.
5. Bag making — Cut and seal into final shape
6. Quality Control — Seal test, adhesion test, gas-tight test
7. Counting & Packing — Machine count and prepare for shipping

Our testing equipment includes:

• Tension testers for lamination strength
• Gas-tight testers to prevent leaks
• 121°C steam kettle to simulate sterilization
• Vacuum sealing machine

• ......
  

What are the most important risk points to pay attention to?

Even good-looking bags can fail if critical steps are overlooked.

Key risks include seal failures¹⁸, delamination, poor barrier performance, air leakage, and printing errors. Proper testing and communication reduce these risks.

Common Risk Points

• Seal failure from low heat or pressure
• Layer delamination from poor adhesive or tension
• Valve misplacement leading to air leaks
• Incorrect material reducing shelf life⁹
• Color shift from improper file handling

We use multiple machines to ensure quality, including pull test machines and leak detectors.

If small quantity⁵ errors happen due to handwork, we’ll refund or make it up on your next order.

Does custom coffee bag have plate fees⁷? How is it charged?

Printing cost is not only per piece — setup fees matter too.

Plate fees apply for gravure printing¹⁴ when quantity⁵ exceeds 5,000 pcs. The fee is charged once per design and size and is not repeated on reorder if nothing changes.

Digital printing has no plate fee. It’s ideal for small batches.

Gravure printing needs custom-made cylinders (plates), but they only need to be paid once unless the size or artwork changes.

This makes gravure more economical in the long run for repeated orders.

Conclusion

Custom coffee bag success relies on clear decisions in printing, materials⁴, structure, and planning for production risks⁸.
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