Pouch Film Width & Master Roll Layout Calculator
Enter your pouch size and the master roll widths you can buy. This YLTPACK calculator shows the flat film width, how many lanes fit on each roll, how much film is lost to trim, and the film area and weight for your order.
Your pouch
Typical value, please confirm with your data.
Typical value, please confirm with your data.
Typical value, please confirm with your data.
Typical value, please confirm with your data.
Master web widths to compare
Add up to 6 widths. The width with the lowest waste is highlighted.
Results
Master web comparison
| Web width | Lanes | Utilization | Waste | Result |
|---|
Master roll layout (recommended width)
How it's calculated
- Flat width (across the web): Pillow = 2 × W + fin seal; 3-side seal (center-fold) = 2 × H; Stand-up (center-fold + bottom gusset) = 2 × H + G.
- Repeat (cut length along the web): Pillow = H; 3-side seal and stand-up = W.
- Lanes = floor((master web width − 2 × edge trim) ÷ flat width).
- Utilization = lanes × flat width ÷ master web width. Waste = 1 − utilization, so edge trim counts as waste.
- Film per pouch (m²) = flat width × repeat ÷ 1,000,000, with both in mm.
- Order area (m²) = film per pouch × quantity × (1 + process waste).
- Weight (kg) = area (m²) × thickness (µm) × density (g/cm³) ÷ 1000.
- Film to buy = order area ÷ utilization at the recommended web width.
- Default assumptions: fin seal 10 mm, edge trim 5 mm per side, process waste 5% and density 1.0 g/cm³ are typical values, please confirm with your data. Registration marks, extra seal allowances and roll core waste are not included.
- Imperial display uses 25.4 mm per inch, 1 mil = 25.4 µm, 10.7639 ft² per m², 2.20462 lb per kg and 28.3495 g per oz. Calculations always run in metric.
How to use
Enter your pouch
Choose the pouch type and enter width and height, plus gusset depth for stand-up pouches. Adjust fin seal and edge trim to match your machine.
Add master web widths
List up to 6 roll widths you can source. Results update instantly as you type, and you can switch between metric and imperial at any time.
Read the result
Check lanes, waste and the highlighted lowest-waste width. Use the film area and weight for budgeting, or send us the numbers for a layout proposal.
A worked example
Default values: pillow bag, W 120 mm, H 200 mm, fin seal 10 mm, edge trim 5 mm per side, 50,000 pouches, 100 µm film, density 1.0 g/cm³, 5% process waste, master webs 1000, 1100, 1250 and 1300 mm.
| Step | Calculation and result |
|---|---|
| Flat width and repeat | 2 × 120 + 10 = 250 mm flat width; repeat = 200 mm. |
| Lanes and waste | 1000 mm: 3 lanes, 75.0% utilization, 25.0% waste. 1100 mm: 4 lanes, 90.9%, 9.1%. 1250 mm: 4 lanes, 80.0%, 20.0%. 1300 mm: 5 lanes, 96.2%, 3.8%. The 1300 mm web has the lowest waste. |
| Film per pouch | 250 × 200 ÷ 1,000,000 = 0.05 m², which is 0.05 × 100 × 1.0 = 5 g per pouch. |
| Order area | 0.05 × 50,000 × 1.05 = 2,625 m². |
| Order weight | 2,625 × 100 × 1.0 ÷ 1000 = 262.5 kg. |
| Per 10,000 pouches | 0.05 × 10,000 × 1.05 = 525 m², or 52.5 kg. |
| Film to buy at 1300 mm | 2,625 ÷ 0.9615 = 2,730 m², about 273 kg. |
Frequently asked questions
Why does a wider master web not always give less waste?
Lanes must be a whole number. A wider web may leave a strip too narrow for one more lane, and that strip becomes waste. Comparing several widths shows which one fits your flat width best.
Why does a stand-up pouch use 2 × H + G?
The film is center-folded to form the front and back panels, and the bottom insert adds the gusset depth G to the flat width. Exact bottom-seal allowances vary by design, so confirm them with our engineers.
What should I enter for process waste?
It covers start-up, printing and bag-making losses. 5% is a typical value, please confirm with your data.
Which density should I use for laminated film?
Use the density from your film supplier's data sheet. PET/PE laminates are often around 1.1-1.2 g/cm³ and PE around 0.92 g/cm³; these are typical values, please confirm with your data.
Is this result a price quote?
No. It estimates film width, layout and weight for planning. Final specifications and prices are confirmed in your quotation.
Related tools
Have a project in mind?
Share your pouch size, material and quantity. Our engineers can review the layout and propose a master roll plan.
Get a Free QuoteContact Shenzhen Yongliantai New Material Technology Co., Ltd. [email protected] +8618219445665
Results are estimates for planning purposes. Final specifications and prices are confirmed in your quotation.