A kraft bag is the final layer of a takeaway order before it reaches the customer and one of the most visible expressions of the brand on the street. Yet bag selection cannot be reduced to width, height or paper grammage. Order weight, pack arrangement, drink stability, base area, gusset opening, handle attachment, humidity and carrying time must work together. An oversized bag lets products move; a narrow bag crushes boxes; a weak base or unsuitable handle puts a well-prepared order at risk. This guide treats the printed kraft bag not simply as promotional packaging, but as a measurable carrying system.
Define the real order profile by weight and arrangement
Before setting bag dimensions, list the typical orders: a single burger meal, a two-person order, a family bundle and a drink-heavy combination create different load patterns. Total weight alone is not enough; the position of the centre of gravity and the way packs press on the base also matter.
Prepare both the most common order and a heavier but realistic upper case for testing. Put heavy items at the bottom, seat wide boxes fully on the base and stabilise cups in a separate carrier where possible. The bag can then cover most daily orders safely without being unnecessarily oversized for an exceptional combination.
- Typical and high-weight order scenarios
- Total weight and centre-of-gravity position
- Loading order for boxes, bowls, sauces and drinks
- Average carrying time from restaurant to customer
Size the width, gusset and base around the product layout
The bag width should accept the widest box without force, while the side gusset must create enough volume for packs to remain upright when the bag opens. If the gusset is too shallow, the sides stretch, the base cannot open flat and the handle attachments carry extra stress. An oversized gusset gives boxes room to slide and tip during transport.
Base dimensions depend not only on the outer size of the box but also on folding and gluing allowances. Wide burger or pizza-slice packs need a supporting base, while tall narrow orders can be penalised by excess paper and storage volume. Loading real packs into the sample and checking that it stands on its own is more reliable than approving dimensions from a table alone.
- Internal base size suited to the widest pack
- Safe closure and grip allowance above product height
- Fully opening side gussets and a flat-standing base
- Controlled clearance that limits pack movement
Match the handle style to the load and use case
Twisted-paper, flat-paper and die-cut handles create different carrying experiences. Twisted handles are comfortable to grip and common for restaurant orders. Flat handles can be efficient for stacking and automated production. Die-cut handles offer a clean appearance, but load distribution across the top of the bag and user comfort require separate testing.
Handle strength depends on more than the handle material. Patch area, adhesive, paper grain and distance from the bag edge determine attachment strength together. Placement too close to the top or side can initiate tearing, while a short handle reduces hand clearance on bulky orders. Approve the handle through a walking test with a filled bag.
- Twisted, flat or die-cut handle matched to the use case
- Adequate handle patch and bonding area
- Grip clearance for gloved hands
- Repeated lifting and short walking test
Assess paper weight together with humidity and journey time
Higher grammage does not automatically produce a safer bag. Fibre structure, moisture content, machine direction and gluing quality directly affect carrying performance. A lightweight short-distance order and a heavy order of steaming food carried for longer should not automatically use the same material standard.
Steam from hot packs can condense inside the bag and soften paper, especially around the base and side seam. Food should not contact the carrier directly; leak-prone products need secondary protection, and ventilation should be solved at product-pack level. The carrier bag is the final layer of the packaging system, not a substitute for leak control.
- Paper grade and grammage matched to order weight
- Base and side-seam behaviour in humid conditions
- Secondary protection for leak-prone foods
- Dry and stable storage conditions
Plan print around folds, handles and gluing areas
Position logos and messages for visibility when the bag is opened and carried, not only when it lies flat. Important text on a side gusset may fold out of view, graphics near the base can scuff and heavy ink beneath a handle patch can affect bonding. Artwork should follow the safe zones of the production template.
Natural kraft changes colour reproduction compared with white paper. Light tones are influenced by the substrate, while large heavy ink areas can raise drying, cracking or rub risks. Review a print sample on the actual paper for brand-critical colours, and test any barcode or QR code outside creases with sufficient contrast.
- Front-facing logo position on the open bag
- Safe areas clear of gussets, folds and handle patches
- Real colour proof on the selected kraft paper
- Rub, drying and readability checks
Run a filled-bag carry test before mass production
Fill the sample with the intended products and test it at the heaviest realistic order weight. Let it stand for a defined period, then lift it repeatedly and simulate stairs and a short walk. Record handle elongation, base opening, seam separation, paper tearing and product tipping.
One successful bag is not enough. Test several samples with the same load and duration, and write the acceptance criteria into the order record. Preserve the approved size, paper code, grammage, handle, patch, adhesive and print revision for repeat orders. The kraft bag then carries not only the brand, but a predictable delivery standard.
- Target and upper-limit load tests with real products
- Holding, repeated lifting and walking simulation
- Written criteria for handle, base, seams and pack stability
- Technical specification and approved sample for repeat orders