How to Determine the Correct DoyPack Size?
Practical Steps, Measurement Comparisons, and Application Guide
Choosing the wrong doypack packaging size can result in the product appearing empty inside, not standing upright on the shelf, or causing various problems during filling and logistics processes. Therefore, focusing solely on weight information is insufficient when choosing the size. Factors such as the physical structure of the product, how the packaging sits on the shelf, and the usage scenario must be considered together. Simple calculations and practical checks are sufficient to arrive at the correct size.
1. Determining the volume occupied by the product in the packaging.
It's important to remember that weight information alone isn't sufficient. Products of the same weight may occupy different volumes in a doypack package.
Practical information:
- Powder products: They take up more volume.
- Granular products: Occupy a medium volume.
- Liquid products: Volume is more clearly defined.
- Multi-piece products: Requires space for clearance.
If the product isn't compressed and air is trapped inside the packaging, it makes more sense to choose a larger size.
2. Shelf Space Analysis
Because packaging is displayed on shelves rather than on paper, shelf mathematics is of great importance. The following points need to be determined:
- Shelf depth (cm)
- Shelf height (cm)
- How many products can be placed in a row?
Practical tips:
- Very tall, narrow-bottomed doypack: Risk of tipping over on the shelf.
- Wide base and balanced height: Ensures a stable stance.
If shelf space is limited, unnecessarily large doypack sizes should be avoided.
3. Doing a Test Fill
The most common and accurate method for choosing packaging size is to make a decision through a trial filling:
Application steps:
- Weigh the product.
- Perform a test filling with the selected doypack size.
- Leave 10-15% space at the top.
- Check the shape of the packaging after sealing.
A doypack that's filled to the brim isn't the correct size.
4. Choosing the Right Doypack Size According to Product Type
Product Type | Proposed Doypack Size Approach | From where |
| Powder product | One size larger according to weight. | An air gap is required. |
| Granular product | Standard size | It settles in a balanced way. |
| Liquid product | Measurement close to net volume. | Fluid structure |
| Partial product | Wide-based measurement | Unbalanced load |
| Heavy product | Short & wide sole | Shelf stability |
This table can be used as a basic reference for selecting doypack bag sizes .
5. Checking Compatibility with the Filling Machine
Packaging dimensions must be suitable for the filling line. Points to consider:
- Is the opening width compatible with the machine?
- Within the altitude sensor range?
- Should enough margin be left for closure?
Doypack sizes that are not compatible with the machine negatively affect production speed.
6. Considering the Use Case
The right size doesn't just provide an advantage on the shelf; it should also offer a pleasant experience during use. Things to consider:
- Overfilled packaging: There is a risk of spillage when opening.
- Very large packaging: It may give the impression that there is little product inside.
- Balanced size: Provides controlled and comfortable use.
User experience is a key criterion in choosing the right packaging size.