Custom Printed Paper Bags for Food Packaging

Last Updated: November 2025
Reading Time: 9 minutes
Author: Papacko Content Team

Introduction

Your customer walks out with your food in a plain white bag. Three blocks later, they’ve forgotten which restaurant it came from.

Custom printed paper bags turn every takeout order into mobile advertising. Your logo, your colors, your brand message walking through neighborhoods, sitting on office desks, posted on social media. But getting custom bags right means understanding printing limitations, MOQ requirements, and design specs that actually work at production scale.

In this guide, you’ll learn:

•Paper bag types and when to use each (flat, gusset, SOS, handle styles)

•Printing methods: flexographic vs digital vs screen printing

•Design specifications (bleed, safe zones, color matching)

•MOQ requirements and cost breakdowns (10k-50k minimum orders)

•Handle options and structural considerations

Paper Bag Types for Food Packaging

Flat Paper Bags (No Gusset)

Construction:

•Simple folded paper bag, no side expansion

•Sealed on three sides, open at top

•Flat profile when empty

•Minimal internal volume

Capacity: 1-5 lbs (depending on size and paper weight)

Best For:

•Sandwiches, wraps (single items)

•Bakery items (baguettes, cookies in boxes)

•Small takeout orders

•Merchandise (retail, gift items)

Sizes Available:

•Small: 6″ × 9″ (sandwich bag)

•Medium: 8″ × 10″ (sub sandwich, small orders)

•Large: 10″ × 13″ (bakery items, larger portions)

Printing Area: Both sides available, maximum visibility

Cost: $0.05-0.10 per bag (before custom printing)

Advantages:

•Largest printable area (front and back flat surfaces)

•Most cost-effective for simple designs

•Easy to stack and store

•Good for single-item packaging

Limitations:

•No expansion for bulky items

•Limited capacity

•Not ideal for multiple items or liquids

SOS Bags (Self-Opening Style / Gusseted Bottom)

Construction:

•Square bottom that opens automatically when filled

•Pleated sides (gussets) allow expansion

•Stands upright when loaded

•Most common takeout bag style

Capacity: 5-20 lbs (depending on size and paper weight)

Best For:

•Multi-item takeout orders

•Groceries, produce

•Bulk bakery items

•Restaurant delivery (stands upright in car)

Sizes Available:

•#2: 4.5″ × 2.5″ × 8″ (small snacks)

•#6: 6″ × 3.5″ × 11″ (standard lunch)

•#10: 6.5″ × 4″ × 13″ (large lunch, small dinner)

•#16: 7.5″ × 4.5″ × 16″ (family meal, groceries)

•#20: 8.5″ × 6″ × 16″ (extra large orders)

Printing Area: Front panel (most visible), side panels available

Cost: $0.08-0.15 per bag (before custom printing)

Advantages:

•Self-standing (easy for customers to pack/carry)

•Higher capacity than flat bags

•Professional appearance

•Versatile for various food types

Limitations:

•Reduced printable area (gussets interrupt design)

•More expensive than flat bags

•Bulkier to store

Handled Paper Bags (Shopping Bag Style)

Construction:

•SOS-style base with attached handles

•Reinforced top edge for handle attachment

•Various handle types (twisted paper, flat, rope)

Capacity: 10-30 lbs (depending on handle strength and paper weight)

Best For:

•Large takeout orders (family meals)

•Catering delivery

•Retail food products (gift baskets, bulk items)

•Premium positioning (upscale restaurants)

Handle Types:

Twisted Paper Handles:

•Made from kraft paper twisted into rope

•Cost-effective ($0.02-0.03 per bag add-on)

•10-15 lb capacity

•Most common for food service

Flat Paper Handles:

•Wide flat paper strips

•Comfortable to carry

•15-20 lb capacity

•$0.03-0.04 per bag add-on

Cotton Rope Handles:

•Durable, reusable feel

•Premium appearance

•20-30 lb capacity

•$0.05-0.08 per bag add-on

•Best for upscale brands

Die-Cut Handles (Punched from bag):

•Handles cut directly from bag material

•No additional material cost

•Lower capacity (5-10 lbs)

•$0.01-0.02 per bag add-on (die-cutting cost)

Sizes Available:

•Small: 8″ × 5″ × 10″ (boutique lunch orders)

•Medium: 10″ × 6″ × 12″ (standard dinner orders)

•Large: 12″ × 7″ × 15″ (family meals, catering)

•XL: 16″ × 8″ × 19″ (large catering, retail)

Printing Area: Front and back panels, large visible area

Cost: $0.15-0.30 per bag (before custom printing, with handles)

Advantages:

•Easiest to carry (hands-free comfort)

•Premium appearance

•Reusable (customers keep for shopping)

•Mobile advertising (carried through public spaces)

Limitations:

•Most expensive option

•Higher MOQ often required

•Complex production (handle attachment)

Paper Material Options

Kraft Paper (Natural Brown)

Specifications:

•60-120 gsm (grams per square meter) depending on bag size

•Natural brown color (unbleached)

•Recyclable and biodegradable

•Textured surface

Advantages:

•Eco-friendly perception (unbleached, natural look)

•Strong and durable (fiber structure intact)

•Lower cost than white paper

•Accepts printing well (contrast against brown)

Best Printing Inks: White, black, dark colors (show contrast)

Cost: Baseline reference (cheapest option)

Use Cases: Casual dining, eco-conscious brands, bakeries, cafés

White Kraft Paper (Bleached)

Specifications:

•70-120 gsm

•Bright white finish

•Bleached pulp (processed for whiteness)

•Smooth surface

Advantages:

•Clean, modern appearance

•Full color printing looks vibrant (white background)

•Professional presentation

•Versatile for all brand styles

Best Printing Inks: All colors work well (CMYK full color)

Cost: 10-20% more than natural kraft

Use Cases: Upscale restaurants, bakeries (wedding cakes), retail food products

FSC-Certified Paper

Specifications:

•Available in kraft or white

•Forest Stewardship Council certified

•Chain-of-custody documentation

•Same performance as non-certified

Advantages:

•Sustainability certification (verified responsible forestry)

•Marketing value (FSC logo usage)

•Appeals to eco-conscious customers

•Required for some corporate/government contracts

Cost: 15-25% premium over non-certified (+$0.02-0.05 per bag)

Requirements: FSC trademark license to print FSC logo ($500-1000/year for small businesses)

Use Cases: Eco-conscious brands, corporate clients, government contracts

Grease-Resistant Paper

Specifications:

•Kraft or white with water/oil barrier treatment

•Prevents grease from soaking through

•80-120 gsm (heavier for strength)

Advantages:

•Protects against oil, grease, moisture

•Maintains bag integrity with greasy foods

•Professional appearance (no oil stains visible outside)

Best For: Fried foods, burgers, pizza (in boxes inside bags), pastries with butter

Cost: 20-30% premium over standard kraft

Limitations: Some treatments reduce recyclability (verify with supplier)

Printing Methods for Custom Bags

Flexographic Printing (Most Common)

Process: Raised rubber/polymer plates transfer ink to paper, like a stamp. High-speed rotary press.

Color Options:

•1-6 spot colors (Pantone matching)

•Each color requires separate plate

•Full-color (CMYK) possible but expensive

MOQ: 50,000-100,000 bags (industry standard)

Setup Cost: $500-1,200 (one-time per design)

•Plate creation: $150-300 per color

•Setup/calibration: $200-400

•Amortized over large orders

Lead Time:

•First order: 40-50 days (design approval, plate creation, production)

•Reorders: 25-35 days (plates stored, faster production)

Cost Per Bag: +$0.02-0.04 (for 2-color printing on kraft)

Advantages:

•Lowest cost per unit at high volume

•Excellent for simple designs (logos, text, solid colors)

•Fast production once setup (15,000-25,000 bags/hour)

•Durable, consistent printing

•Best for repeat orders (plates reused)

Limitations:

•High MOQ (not suitable for small businesses testing)

•Poor gradients/photos (spot color limitations)

•Setup cost only worthwhile for large orders

•Design changes require new plates

Best For: Established businesses, consistent orders, simple brand designs

Digital Printing (Lower MOQ)

Process: Direct digital printing (like a large-format printer), no plates required.

Color Options:

•Full CMYK color (unlimited colors)

•Gradients, photos, complex designs

•Variable data printing (different designs in same run)

MOQ: 5,000-10,000 bags (much lower than flexo)

Setup Cost: $100-300 (minimal setup, digital file prep only)

Lead Time: 15-25 days (faster than flexo)

Cost Per Bag: +$0.06-0.10 (significantly higher per unit)

Advantages:

•Low MOQ (accessible for small businesses)

•Full color, high detail (photos, gradients)

•Easy design changes (digital files, no physical plates)

•Fast turnaround

•Test designs before committing to large flexo orders

Limitations:

•Expensive per unit (2-3× flexo cost)

•Slower production (2,000-5,000 bags/hour)

•Color may vary between runs (less consistent than flexo)

•Not cost-effective for large volumes

Best For: New businesses testing designs, seasonal/promotional bags, complex artwork, small-batch specialty products

Screen Printing

Process: Ink pushed through mesh screen stencil onto paper.

Color Options:

•1-3 colors (limited for cost efficiency)

•Excellent color saturation and vibrancy

•Specialty inks available (metallic, fluorescent)

MOQ: 10,000-25,000 bags

Setup Cost: $200-500 (screen creation per color)

Cost Per Bag: +$0.04-0.07 (mid-range)

Advantages:

•Vibrant, bold colors (higher ink density than flexo)

•Specialty inks (metallic gold/silver, fluorescent)

•Good for premium branding

•Mid-range MOQ

Limitations:

•Limited colors (expensive to add colors)

•Slower than flexo (5,000-10,000 bags/hour)

•Not ideal for detailed designs

Best For: Premium brands, boutique restaurants, specialty designs with metallic/unique inks

Design Specifications

File Requirements

Format: Vector files (AI, EPS, PDF) required for best quality

•Raster files (JPG, PNG) acceptable at 300+ DPI minimum

•Text converted to outlines (prevents font issues)

Color Mode:

•Flexographic: Pantone spot colors (PMS matching)

•Digital: CMYK (full color)

•Avoid RGB (screen colors don’t translate to print)

Resolution: Minimum 300 DPI for raster elements (photos, gradients)

File Size: Under 50MB for email transfer (larger files via file sharing)

Dimensions and Safe Zones

Printable Area: Varies by bag size and type

Example: Medium SOS Bag (6″ × 11″ front panel):

•Total panel: 6″ wide × 11″ tall

•Bleed: Add 0.125″ (3mm) on all sides that go to edge

•Safe zone: Keep critical text/logos 0.25″ (6mm) from edges

•Fold zones: Avoid bottom 1″ (bottom fold) and top 1″ (potential folding during packing)

Handle Placement: For handled bags, keep design 1.5-2″ below handle attachment point (handles obscure this area)

Gusset Considerations: For SOS bags, design wraps onto gusset. Test how design looks when bag is both flat and expanded.

Spine/Fold Areas: Ink may crack along fold lines over time. Avoid critical design elements on heavy-fold areas.

Color Matching

Pantone Matching (Flexographic):

•Select PMS colors from Pantone guide

•Colors matched precisely during production

•Provide Pantone numbers to supplier (e.g., “PMS 186 C” for red)

•Expect 95%+ accuracy to Pantone swatch

CMYK Full Color (Digital):

•Colors built from Cyan, Magenta, Yellow, Black

•More color variation between runs

•Proof approval critical before production

•Expect 85-90% match to screen colors (monitors not calibrated to print)

Kraft Paper Considerations:

•Brown background affects color appearance

•White underprint may be needed for accurate color (adds cost)

•Test colors on kraft substrate before production

•Dark colors (black, navy, forest green) work best on natural kraft

White Paper:

•All colors print accurately

•No underprint needed

•Best for full-color photography

Typography and Legibility

Minimum Font Sizes:

•Body text: 8pt minimum (12pt recommended for readability)

•Phone numbers, URLs: 10pt minimum

•Logos: Scale appropriately (test visibility from 6 feet away)

Font Weights:

•Avoid very thin fonts (under 1pt stroke weight) – may not print cleanly

•Bold fonts work best for small text

•Script fonts: Use sparingly, keep large (12pt+)

Contrast:

•High contrast = readable (black on white, white on kraft)

•Low contrast = hard to read (light gray on white, yellow on kraft)

Kerning/Tracking: Avoid very tight spacing (ink spread may cause letters to touch)

MOQ and Cost Breakdown

Flexographic Printing Costs

MOQ: 50,000 bags (industry standard)

Example: Medium SOS Bag (6″ × 11″) on Kraft, 2-Color Logo

Base Bag Cost: $0.08 per bag (blank bag)
Printing Cost: $0.03 per bag (2-color flexo)
Setup Fee: $800 (one-time)
Shipping: $300-500 (depending on location)

Total First Order:

•50,000 bags × $0.11 = $5,500

•Setup: $800

•Shipping: $400

•Total: $6,700 ($0.134 per bag)

Reorders (same design, plates stored):

•50,000 bags × $0.11 = $5,500

•Setup: $0 (plates reused)

•Shipping: $400

•Total: $5,900 ($0.118 per bag)

Break-Even: After 2-3 orders, flexo cost per bag is lowest option.

Digital Printing Costs

MOQ: 5,000-10,000 bags

Example: Medium SOS Bag (6″ × 11″) on White, Full-Color Design

Base Bag Cost: $0.10 per bag (white kraft)
Printing Cost: $0.08 per bag (full-color digital)
Setup Fee: $200
Shipping: $100-150 (smaller quantity)

Total First Order (10,000 bags):

•10,000 bags × $0.18 = $1,800

•Setup: $200

•Shipping: $125

•Total: $2,125 ($0.2125 per bag)

Per-Unit Cost: Nearly 2× flexo, but accessible for small businesses

When It Makes Sense: Testing designs, seasonal promotions, under 25,000 annual bag usage

Cost Comparison Table

Printing Method	MOQ	Setup Cost	Cost Per Bag	Best For
Flexographic	50,000+	$500-1,200	$0.11-0.14	High volume, simple designs
Digital	5,000-10,000	$100-300	$0.18-0.22	Small volume, full color
Screen Print	10,000-25,000	$200-500	$0.15-0.19	Premium, specialty inks

Alt Text: Decision tree for choosing printing method based on monthly bag usage volume and design complexity
Filename: blog_009_mermaid_01.png

Branding Strategy for Food Packaging

Essential Brand Elements to Include

Logo (Required):

•Primary placement: Front panel, centered or top-center

•Size: Large enough to read from 6 feet (typically 2-4″ height)

•Color: High contrast against bag color

Business Name (Required):

•If not in logo, add as text

•Placement: Near logo or bottom of front panel

Contact Information (Highly Recommended):

•Phone number (especially for takeout/delivery businesses)

•Website URL (shorten if needed: “yoursite.com” not “https://www.yoursite.com”)

•Social media handles (@yourbrand on Instagram)

•Placement: Bottom of bag or side panel

Tagline/Value Proposition (Optional):

•Brief descriptor: “Fresh Daily”, “Family Owned Since 1995”, “100% Organic”

•Placement: Below logo or on side panel

Sustainability Message (If Applicable):

•“Recyclable”, “FSC Certified”, “Made from Recycled Paper”

•Placement: Bottom corner or back panel

QR Code (Growing Trend):

•Links to menu, loyalty program, social media

•Placement: Side or back panel (not primary design area)

•Size: Minimum 1″ × 1″ for reliable scanning

Design Trends for Food Packaging (2025)

Minimalist/Clean:

•Simple logo, ample white/kraft space

•Limited colors (1-2 colors)

•Modern, sophisticated

•Examples: Upscale cafés, juice bars

Vintage/Rustic:

•Hand-drawn fonts, illustrations

•Natural kraft paper

•Warm, nostalgic feel

•Examples: Bakeries, family restaurants, delis

Bold/Colorful:

•Bright colors, patterns

•Energetic, playful

•Full-color digital printing

•Examples: Dessert shops, food trucks, fast-casual

Eco-Conscious:

•Natural kraft, minimal ink

•Sustainability messaging prominent

•Green/earth tones

•Examples: Organic restaurants, health food, farm-to-table

Illustrative/Artistic:

•Custom illustrations, characters

•Storytelling through design

•Unique brand personality

•Examples: Specialty cafés, artisan bakeries

Frequently Asked Questions

1. What’s the minimum order quantity for custom printed bags?

Flexographic printing: 50,000-100,000 bags (industry standard)

Digital printing: 5,000-10,000 bags (lower MOQ option)

Screen printing: 10,000-25,000 bags (mid-range)

Workaround for very small businesses: Order 5,000 plain bags + custom stickers/stamps for branding (MOQ as low as 500 stickers). Not as professional but accessible.

Timeline consideration: At 200 bags/day, 50,000 bags = 250 days (8+ months). Order quantity that lasts 6-12 months.

2. Can I print full-color photos on kraft paper bags?

Yes, with caveats:

White underprint required: Brown kraft background affects color accuracy. Suppliers can add white ink layer first, then print colors on top.

•Cost: +$0.02-0.04 per bag for white underprint

•Doubles ink layers, increases complexity

Digital printing recommended: Full-color photos work best with digital, not flexographic.

Better alternative: Use white kraft bags for full-color photography (no underprint needed, colors accurate).

Cost comparison:

•Full-color on white kraft (digital): $0.18-0.22 per bag

•Full-color on natural kraft with underprint (digital): $0.20-0.26 per bag

3. How long does production take?

Flexographic (first order): 40-50 days

•Design approval: 3-5 days

•Plate creation: 7-10 days

•Production: 15-20 days

•Shipping: 10-15 days (international), 5-7 days (domestic)

Flexographic (reorders): 25-35 days (plates stored, skip creation step)

Digital printing: 15-25 days (no plates needed, faster setup)

Rush orders: +20-30% cost for expedited production (20-30 days minimum)

Pro tip: Reorder when you have 3-4 months supply remaining, avoid rush fees.

4. Can I order different bag sizes with the same design?

Yes, most suppliers allow this to meet MOQ:

Example:

•30,000 medium bags (6″ × 11″)

•20,000 large bags (7.5″ × 16″)

•Total: 50,000 bags (MOQ met)

Requirements:

•Same design (logo, colors)

•Design scaled proportionally for each size

•Same printing method

•Ordered in single production run

Setup cost: Some suppliers charge separate setup per size, others include scaling in base setup. Clarify before ordering.

Not allowed: Different designs per size (each design requires separate MOQ).

5. What file format should I provide for printing?

Best: Vector files (AI, EPS, PDF with embedded fonts)

•Scalable without quality loss

•Clean edges and text

•Preferred by all printers

Acceptable: High-resolution raster (PNG, JPG) at 300+ DPI

•Must be large enough for final print size

•May show pixelation if scaled up

•Requires conversion to vector by supplier (may incur fee)

Avoid: Low-res files under 300 DPI, RGB color mode (use CMYK or Pantone)

If you don’t have design files: Many suppliers offer design services ($100-500 depending on complexity).

6. Do handles add significant cost?

Yes:

Twisted paper handles: +$0.02-0.03 per bag
Flat paper handles: +$0.03-0.04 per bag
Cotton rope handles: +$0.05-0.08 per bag

Example: Medium handled bag with twisted paper handles:

•Base bag: $0.12

•Printing (2-color): $0.03

•Handles: $0.03

•Total: $0.18 per bag (vs $0.15 for non-handled)

Capacity increase: Handles support more weight (15-30 lbs vs 5-10 lbs for non-handled).

Value: Handles improve customer experience significantly (easier to carry), worth the premium for most food businesses.

Break-even: Upcharge customers $0.25-0.50 for delivery bags with handles, covers cost and generates margin.

7. How do I verify my supplier uses FSC-certified paper?

Request documentation:

1.FSC certificate number – Verify at info.fsc.org

2.Chain-of-custody certificate – Proves paper tracking from forest to product

3.Recent audit report – FSC audits annually or semi-annually

Check supplier credentials:

•Supplier must have FSC certification to sell FSC-labeled products

•License number should be visible on their website/documentation

FSC logo usage:

•If you want FSC logo on bags, YOU need FSC trademark license ($500-1000/year)

•Supplier provides FSC-certified bags, but logo printing requires your license

•Alternative: Market as “FSC-certified” without printing logo (still legitimate)

Red flags:

•“Eco-friendly” claims without FSC certification number

•Refusal to provide documentation

•Self-certified without third-party verification

Conclusion

Custom printed paper bags transform takeout packaging into brand assets that amplify your business with every order.

Key Takeaways:

1.Bag types: Flat bags for single items, SOS bags for multi-item orders, handled bags for premium presentation

2.Printing methods: Flexographic for high volume (50k+ MOQ, $0.11-0.14/bag), digital for small runs (5k+ MOQ, $0.18-0.22/bag)

3.Design specs: Vector files required, Pantone colors for flexo, CMYK for digital, 0.25″ safe zone from edges

4.MOQ strategy: Start with digital printing to test designs, switch to flexographic when volume justifies (2,000+ bags/month)

5.Branding essentials: Logo, business name, contact info (phone + website), sustainability messaging if applicable

6.Handle selection: Twisted paper handles ($0.02-0.03 add-on) best value for most food businesses

Order samples before committing to production runs – test bag durability with your actual food products.

Related Resources

•Food Packaging Containers – Complete packaging solutions

•Sustainable Paper Packaging – FSC certification guide

•Packaging Accessories – Complementary branded items

Ready to Design Custom Printed Paper Bags?

Papacko supplies custom printed paper bags with flexible MOQ options and expert design support.

Why choose Papacko:

•Flexible MOQ: Digital printing from 5,000 bags, flexographic from 50,000

•Free design consultation: We help optimize your design for production

•FSC-certified paper: Chain-of-custody documentation provided

•Sample program: Order printed samples before bulk production

•Multiple handle options: Twisted paper, flat, rope, die-cut

•In-house design team: Design services available if you need artwork created

Get in touch:

•Request a Quote – Custom bag pricing with your specifications

•Free Design Consultation – Optimize your artwork for printing

•Sample Kit – Test bag sizes and paper types with your products