When it comes to poly bags, not all styles are created equal. Two of the most common formats in flexible packaging are layflat bags and gusseted bags. At first glance they look similar — but each has its own advantages depending on what you’re packaging and how it’s handled.
What Is a Layflat Bag?
A layflat bag is a simple, flat poly bag with sealed sides and one open end. When empty, it lies completely flat — just like the name suggests.
- Sealed on the bottom or side
- No folds or expansions
- Clean, flat surface for labeling or printing
- Great for uniform or low-profile items
Layflat bags are typically used for parts packaging, clothing, literature and promotional materials, and food service items. They’re ideal for products that don’t need extra depth.
What Is a Gusseted Bag?
A gusseted bag has extra folds (gussets) on the sides or bottom that let the bag expand outward. At M Plastics, we primarily manufacture side gusseted bags with a bottom seal, especially for food and industrial use.
- Expands to fit bulky or irregularly shaped items
- Increases internal volume without a larger footprint
- Often used for box liners, bread bags, produce, and hardware
Gusseted bags are the go-to choice when extra space is needed — and they run well on automated lines in wicketed formats.
Side-by-Side Comparison
| Feature | Layflat Bag | Gusseted Bag |
|---|---|---|
| Shape when empty | Completely flat | Folds along sides or bottom |
| Expansion | None | Expands outward when filled |
| Best for | Flat, uniform items | Bulky or irregular items |
| Common format at M Plastics | Plain or printed, side or bottom seal | Bottom seal with side gussets, plain or wicketed |
How to Choose the Right Bag
- Use layflat bags when you’re packaging lightweight or low-profile items and want a clean, flat presentation.
- Use gusseted bags when you need extra volume or are lining a box, bin, or tray.
Some customers use both — layflat for inner product protection and gusseted for outer bulk packaging.
Final Thoughts
The choice between layflat and gusseted comes down to the application. M Plastics manufactures both styles from LDPE in custom sizes, mil thicknesses, and print options up to 6 colors. Not sure which fits your product? Request a quote and we’ll help you decide.
Have a Packaging Question?
M Plastics manufactures LDPE bags and film in Los Angeles with in-house extrusion and printing. Tell us what you're packaging and we'll help you spec the right bag.
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