Layflat vs. Gusseted Bags — What’s the Difference?

When it comes to poly bags, not all styles are created equal. Two of the most common formats in the flexible packaging industry are layflat bags and gusseted bags. At first glance, they might look similar — but each has its own advantages depending on what you're packaging and how it’s being handled. 

This post breaks down the differences between layflat and gusseted bags so customers can better understand which option fits their needs. 

What Is a Layflat Bag?

A layflat bag is a simple, flat plastic bag with two sealed sides and one open end. When empty, it lies completely flat — just like the name suggests.

Common features: 

• Sealed on the bottom or side

• No folds or expansions

• Clean, flat surface for labeling or printing

• Great for uniform or flat items

Layflat bags are typically used for: 

• Parts packaging (manual or hand-inserted)

• Clothing, literature, or promotional materials

• Food service items

• Heat sealing and impulse sealing

• They're ideal for low-profile products that don’t require extra depth or expansion. 

What Is a Gusseted Bag?

A gusseted bag has extra folds (gussets) on the sides or bottom that allow the bag to expand outward. At M Plastics, we primarily manufacture side gusseted bags with a bottom seal, especially for food and industrial use.   

Common features:

• Expands to fit bulky or irregularly shaped items

• Increases internal volume without increasing bag size

• Often used for box liners, bread bags, produce, or hardware

• They’re the go-to choice when extra space is needed — and they pack more efficiently when used in shipping or automated lines.

Visual and Functional Differences

Feature	Layflat Bag	Gusseted Bag
Shape When Empty	Completely flat	Folds along sides or bottom
Expansion	None	Expands outward when filled
Storage Efficiency	High (compact)	Medium (depends on fold)
Best For	Flat items	Bulky or irregular items
Common Format at M Plastics	Plain or printed, side seal or bottom seal	Bottom-seal with side gussets, plain or wicketed

How to Choose the Right Bag

Here are a few quick tips to help customers decide: 

• Use layflat bags when: You’re packaging lightweight or low-profile items and want clean, flat presentation. 

• Use gusseted bags when: You need extra volume or are lining a box, bin, or tray with a flexible material.

 In some cases, clients may use both formats — one for inner product protection (layflat) and one for outer bulk packaging (gusseted).

Final Thoughts

The choice between layflat and gusseted bags depends on the application. At M Plastics, we manufacture both styles using high-quality LDPE, available in custom sizes, gauges, and print options. Knowing the difference helps ensure your packaging is efficient, cost-effective, and perfectly suited to the job.